Dynamic analysis and experimental validation of vibration sensing for machining thin-walled component

Machining complex thin-walled components, such as compressor disks and casings in aircraft engines, is a challenging task because distributed deformation and vibration renders poor precision and quality in final products. However, the harsh working conditions such as cutting fluids hinder workpiece vibration monitoring, not to mention investigation into the vibration principle during cutting. Aiming to decouple and quantify the effects of multiple cutting process parameters on thin-walled part vibration, this paper employs a plate dynamic model for an annular workpiece under constraints emulating those of a two-sided turning machine. Therefore, a boundary value problem is formulated and the solution procedure is presented in details. With modal analysis, the dynamic model is numerically verified with finite element analysis (FEA). Also, an eddy-current sensing approach is provided as a simple yet practical method for vibration measurement. Experiments are carried out to justify the proposed method and validate the stability of eddy-current sensing under the harsh environmental condition.