Prediction of Surface Location Error Considering the Varying Dynamics of Thin-Walled Parts during Five-Axis Flank Milling
Round 1
Reviewer 1 Report
This research proposes a computationally effective and practical technique for SLE prediction in five-axis flank milling that takes into account the variable dynamics of thin-walled components, including a computationally efficient dynamics model and a practical SLE prediction method. The paper can be accepted after the revisions.
My comments are given below.
-The similarity index of the paper is 31% (Ithenticate).
-In the text, some reference numbers are not visible.
-Some recent studies can be added in the literature
e.g. A hybrid decision-making approach to prevent chatter vibrations, Applied Soft Computing
- It is important to provide details on the work done with the finite element method for the FRF calculation.
Author Response
Please see the attachment.
Author Response File: 
Author Response.docx
Reviewer 2 Report
The manuscript presents original results related to the development of a method for predicting the error in determining the coordinates (spatial position) of the surface of 3D thin-walled parts in five-axis milling taking into account the dynamics of the processing process.
An algorithm scheme is proposed for predicting the error in determining the position of the surface of a part, based on the analysis of the results of numerical simulation of the vibration process and the additional forces that arise when cutting thin-walled parts. Modeling of forces and vibrations arising during cutting is proposed to be performed taking into account the properties of the material, cutting modes, and a set of tool characteristics.
The paper also presents the results of experimental measurements of vibration parameters for thin-walled aluminum part in five-axis flank milling.
The manuscript is well structured.
Good quality illustrations.
The conclusions are specific and based on the assessment of the authors of the obtained original experimental and theoretical results.
The results obtained may be of great interest to a wide range of specialists, graduate students and students performing research on the dynamics of cutting treatment equipment and specializing in the processing of complex and thin-walled structural elements by five-axis flank milling.
The quality of the manuscript should be improved
1. The conclusion of the authors about the effectiveness of the proposed model in section “4.2. Verification of dynamics model for thin-walled part in five-axis flank milling”, as well as in conclusion, does not seem to be entirely convincing. The values of errors in determining the parameters, obtained by the proposed method, are 1.5 to 2 more than in finite element simulation, as shown in Figure 11 and Table 1.
Conclusions about the effectiveness of the technique, made on the basis of a comparison of DOF data, can be accepted if the same error values are obtained when using the considered methods. It is likely that by increasing the DOF in the proposed technique, the resulting accuracy will be improved. It is required to compare the DOFs in the both methods required to obtain the same error values in the calculations. It is for this case that the required duration of the calculations should be compared.
2. It is required to additionally explain the reasons for the significant increase in surface location error at the initial and final positions in the processing direction in Figure 14.
Design notes:
1. Omitted references to equations should be added (Line 136, 158,159,184).
2. Missing figure references should be added (Line 104, 140,169, 186, 190, 204, 214, 223, 268, 275, 285, 287, and 297).
Author Response
Please see the attachment.
Author Response File: Author Response.docx
Reviewer 3 Report
Excellent paper. I think it deserves to be published. However, there are many minor typos erro in the manuscript which must be corrected.
Below the list:
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Author Response
Please see the attachment.
Author Response File: Author Response.docx
