A frequency-domain solution for efficient stability prediction of variable helix cutters milling

Jin, Gang; Zhang, Qichang; Qi, Houjun; Yan, Bing

doi:10.1177/0954406214522614

Cited by 18 publications

(26 citation statements)

References 24 publications

(36 reference statements)

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“…However, most of them were developed with the aim of constructing stability charts for milling processes, such as the analysis of the milling system with runout [25], with variable pitch/helix cutter [26][27][28][29][30], with variable-spindle speed [31][32][33], or with serrated cutter [34,35]. In order to verify the proposed method, two typical milling operations are chosen and considered.…”

Section: Verification Of Methodsmentioning

confidence: 99%

See 1 more Smart Citation

A Method for Stability Analysis of Periodic Delay Differential Equations with Multiple Time-Periodic Delays

Jin

et al. 2017

Mathematical Problems in Engineering

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Delay differential equations (DDEs) are widely utilized as the mathematical models in engineering fields. In this paper, a method is proposed to analyze the stability characteristics of periodic DDEs with multiple time-periodic delays. Stability charts are produced for two typical examples of time-periodic DDEs about milling chatter, including the variable-spindle speed milling system with one-time-periodic delay and variable pitch cutter milling system with multiple delays. The simulations show that the results gained by the proposed method are in close agreement with those existing in the past literature. This indicates the effectiveness of our method in terms of time-periodic DDEs with multiple time-periodic delays. Moreover, for milling processes, the proposed method further provides a generalized algorithm, which possesses a good capability to predict the stability lobes for milling operations with variable pitch cutter or variable-spindle speed.

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Section: Verification Of Methodsmentioning

confidence: 99%

“…Considering a system for milling process with variable pitch cutter [29,30] as shown in Figure 3, the mathematical models can be written aṡ…”

Section: Milling With Variable Pitchmentioning

confidence: 99%

A Method for Stability Analysis of Periodic Delay Differential Equations with Multiple Time-Periodic Delays

Jin

et al. 2017

Mathematical Problems in Engineering

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“…Jin et al 22 adapted the variable-pitch zero-order frequency approach 23 for variable helix tools. As with Turner's work, 17 they considered the variable helix tool as a variable pitch scenario by averaging the pitches along the flutes.…”

Section: Variable Helix Millingmentioning

confidence: 99%

Validation of variable helix milling instability islands

Mendieta

Öztürk

Sims

2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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During machining, it is well-known that unstable self-excited vibrations known as regenerative chatter can limit productivity. There has been a great deal of research that has sought to understand regenerative chatter, and to avoid it through modifications to the machining process. One promising approach is the use of variable helix tools. Here, the time delay between successive tooth passes is intentionally modified, in order to improve the boundary of instability. Previous research has predicted that such tools can offer significant performance improvements whereby islands of instability occur in the stability lobe diagram. By avoiding these islands, it is possible to avoid regenerative chatter, at depths of cut that are orders of magnitude higher than for traditional tools. However, to the authors’ knowledge, these predictions have not been experimentally validated, and there is limited understanding of the parameters that can give rise to these improvements. The present study seeks to address this shortfall. A recent approach to analysing regenerative chatter stability is modified, and its numerical convergence is shown to outperform alternative methods. It is then shown that islands of instability only emerge at relatively high levels of structural damping, and that they are particularly susceptible to model convergence effects. The model predictions are validated against detailed experimental data that uses a specially designed configuration to minimise experimental error. To the authors’ knowledge, this provides the first experimentally validated study of unstable islands in variable helix milling, whilst also demonstrating the importance of structural damping and numerical convergence on the prediction accuracy.

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“…Aiming at predicting the stability of milling process with VPC, frequency-domain model [12,13], the Cluster Treatment of Characteristic Roots [14], unified SDM [15], improved FDM [16,17], and improved SDM [18] have been proposed successively. Furthermore, Sims et al [19], Sims [20], Dombovari and Stepan [21], and Jin et al [22,23] proposed efficient methods to predict the stability for VPC and variable helix cutter, while Yusoff and Sims [24] optimized the geometry of variable helix tool to suppress regenerative chatter. Besides, the use of serrated cutters [25] also exhibited good capacity and potential for a higher stable depth of cuts.…”

Section: Introductionmentioning

confidence: 99%

Stability Analysis of Milling Process with Variable Spindle Speed and Pitch Angle considering Helix Angle and Process Phase Difference

Jin

Jiang

Han

et al. 2021

Mathematical Problems in Engineering

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Suppression of milling chatter by disrupting regenerative effect is a well-known method to obtain higher cutting stability domain. In this paper, a dynamic model of the milling process with variable spindle speed and pitch angle considering helix angle and process phase difference is presented. Then, an updated semidiscretization method is applied to obtain the stability chart. After the effectiveness of the proposed method is confirmed by comparisons with the previously published works and the time-domain simulations, lots of analyses are conducted to deeply evaluate the influence of the helix angle, the process phase difference, and feed per tooth on milling stability. Results show that the change of helix angle can result in significant stability discrepancies for both high-speed and low-speed regions. Though the process phase difference has the randomness and immeasurability in the practical application, it has an important influence on the stability and will result in a periodic evolution of the stability with a period π. Also, its recommended values are given for the practical milling process.

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A frequency-domain solution for efficient stability prediction of variable helix cutters milling

Cited by 18 publications

References 24 publications

A Method for Stability Analysis of Periodic Delay Differential Equations with Multiple Time-Periodic Delays

A Method for Stability Analysis of Periodic Delay Differential Equations with Multiple Time-Periodic Delays

Validation of variable helix milling instability islands

Stability Analysis of Milling Process with Variable Spindle Speed and Pitch Angle considering Helix Angle and Process Phase Difference

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