Informativity Enhancing of the Cutting Force Measuring Results while Manufacturing Technology Try-Out of the Samples from Metal and Polymer-Composite Materials for the Strength Testing

Testing of the Flying Vehicles Composite Structures Elements


Аuthors

Bolsunovskiy S. А.*, Pupchin V. A.**, Titov S. A.

Central Aerohydrodynamic Institute named after N.E. Zhukovsky (TsAGI), 1, Zhukovsky str., Zhukovsky, Moscow Region, 140180, Russia

*e-mail: sergey.bolsunovskiy@tsagi.ru
**e-mail: vladimir.pupchin@tsagi.ru

Abstract

Samples manufacturing for the strength test to ensure aviation structures certification, including those from polymer-composite materials, requires milling technology development employing numerical program control equipment, which ensures the required accuracy in size and surface quality, as well as zero damages in the samples, which may affect the results of the experiments being conducted. TsAGI scientific and production complex applies the instrumental software-hardware complex based dynamometric platform from Kistler (Switzerland) to develop milling technology. 
The authors consider specifics of the measurements performed with piezoelectric dynamometers whith limited data acquisition frequency and susceptible to to the  signal amplification of the high-frequency Fourier harmonics, associated with the platform resonant frequency of ~2 kHz. The article presents the results of such amplification impact on the signal. These signal specifics limit the possibilities for the measurements direct analysis, and require special methods application of the signal processing to increase the sampling frequency, retaining at the same time all high-frequency components of the high-order harmonics.
The authors consider development of an algorithm for special processing of the results of milling force measurements with the dynamometric platform by sampling frequency increasing of the received signal, which increases informativity of the technological experiment. 
The article demonstrates the possibility of obtaining more accurate representation of the actual cutting force by the sampling frequency increasing of a single period using data from the other periods in a certain time range. The sampling frequency of the resulting signal is much higher (up to the several tenfold), but the signal is blurred due to the spindle rotation frequency determining error during technological experiment.
To overcome this problem, the authors proposed a method for the spindle speed refining based on the available experimental data. This method involves the spindle speed refining by optimizing the length of the curve that describes the cutting force cyclogram.
This algorithm application enables elimination of the extraneous effects occurring during the signal digitizing and accuracy increase of the cutting force measuring, compared with the algorithms used as part of the Kistler Dynoware software package supplied with the dynamometric platform. The algorithm was implemented as a separate module of the specialized software package for the cutting force measuring results processing.

Keywords:

samples for strength tests, high-speed milling, polymer composite materials mechanical processing, cutting force measuring during milling, dynamometric platform, processing results of cutting force measuring

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