A study on the chatter characteristics of the thin wall cylindrical workpiece

Chang, Jincai; Lai, Guang-Jer; Chen, M.F.

doi:10.1016/0890-6955(94)90080-9

Cited by 17 publications

(7 citation statements)

References 7 publications

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“…In practice, however, the tool keeps engaged with the workpiece at the point of cut and moves along the longitudinal axis of the workpiece continuously during an entire cutting pass. Moreover, the experimental observations that when chatter occurs at some cutting position during turning operations of thin walled workpieces it will last for a period of time has been described in [21,22]. The analogous phenomenon also happened in our previous slender workpieces turning experiments [23].…”

Section: Introductionsupporting

confidence: 66%

Model-based chatter stability prediction and detection for the turning of a flexible workpiece

Zi-sheng

et al. 2018

Mechanical Systems and Signal Processing

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Machining long slender workpieces still presents a technical challenge on the shop floor due to their low stiffness and damping. Regenerative chatter is a major hindrance in machining processes, reducing the geometric accuracies and dynamic stability of the cutting system. This study has been motivated by the fact that chatter occurrence is generally in relation to the cutting position in straight turning of slender workpieces, which has seldom been investigated comprehensively in literature. In the present paper, a predictive chatter model of turning a tailstock supported slender workpiece considering the cutting position change during machining is explored. Based on linear stability analysis and stiffness distribution at different cutting positions along the workpiece, the effect of the cutting tool movement along the length of the workpiece on chatter stability is studied. As a result, an entire stability chart for a single cutting pass is constructed. Through this stability chart the critical cutting condition and the chatter onset location along the workpiece in a turning operation can be estimated. The difference between the predicted tool locations and the experimental results was within 9% at high speed cutting. Also, on the basis of the predictive model the dynamic behavior during chatter that when chatter arises at some cutting location it will continue for a period of time until another specified location is arrived at, can be inferred. The experimental observation was in good agreement with the theoretical inference. Moreover, it is shown that vibration spectrum is more sensitive to the chatter evolution than the signal variance. Specifically, when the cutting operation transfers from stable to unstable state, the corresponding vibration frequency features a shift from the spindle rotation frequency or its harmonics to the critical chatter frequency that slightly varies during the chatter-lasting period.

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Section: Introductionsupporting

confidence: 66%

Model-based chatter stability prediction and detection for the turning of a flexible workpiece

Zi-sheng

et al. 2018

Mechanical Systems and Signal Processing

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“…This phenomenon refers to the cutting force variation due to the dynamic chip thickness formed by regeneration of waviness on both sides of the chip surface. Regarding the flexible workpiece as a single degree of freedom system exclusive of the shell mode [15], the corresponding mathematical chatter model is a delayed differential equation (DDE),…”

Section: Chatter-free Constraintmentioning

confidence: 99%

Dynamic optimization of multipass turning of a flexible workpiece considering the effect of cutting sequence

Zhang

Jing

et al. 2015

Int J Adv Manuf Technol

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In multipass turning of flexible workpieces, the selection of the sequence of cutting passes is as important as the selection of machining parameters (depth of cut, feed rate, and cutting speed). This is because the varying workpiece diameter has an effect on the optimization objective function and constraints. In general, there should be a total of five decision variables in multipass turning optimization problems, that is, the three fundamental machining parameters, the number of cutting passes, and the sequence of cutting passes. However, this issue has been paid little attention in literature. This study presents an effective method for optimizing the cutting sequence and the machining parameters to suppress the deformation and chatter during turning a flexible cantilever tube. The mathematical optimization model distinct from the simplified model used in many previous studies is formulated, where the deformation and chatter constraints are intensively deduced from the dynamic analysis. The optimization problem is solved in two phases. The first phase is to determine the minimum production time for each cutting pass for the predefined depths of cut. A particle swarm optimization is employed to accomplish this step. After that, a dynamic programming technique is adopted to achieve the optimal sequential subdivision of the total depth of cut. A computational experiment elaborates the methodology. The results demonstrate that the proposed method is of generality and more efficient in comparison with other algorithms.

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“…Thin-walled workpieces have a high compliance, and thus, compared to more solid workpieces, self-excited vibrations may occur more easily during machining [2]. The dynamic displacement between the tool and the workpiece leads to a variation of the chip thickness and a wavy workpiece surface.…”

Section: Introductionmentioning

confidence: 99%

Influence of Machining Parameters on Heat Generation During Milling of Aluminum Alloys

et al. 2016

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Thin-walled components, i.e. fuselage frames of airplanes, are prone to an unstable process behavior during milling. Therefore, tools with a chamfer between the cutting edge and the flank face are often used for such machining tasks. During milling, the chamfered area comes into contact with the just cut surface. This contact leads to process damping forces and the induced heat into the workpiece in this contact zone is increased. Furthermore, the amount of induced heat depends on the process parameters. At certain spots on the machined surface this may lead to a local overheating, which can reduce stiffness significantly. When this occurs during milling of a thin-walled component, the component is often regarded as reject. In this paper, the influence of chamfers and process parameters on the induced heat into the workpiece is investigated experimentally. In addition, a simulation which predict the temperature in the workpiece in dependence of the process parameters is presented.

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A study on the chatter characteristics of the thin wall cylindrical workpiece

Cited by 17 publications

References 7 publications

Model-based chatter stability prediction and detection for the turning of a flexible workpiece

Model-based chatter stability prediction and detection for the turning of a flexible workpiece

Dynamic optimization of multipass turning of a flexible workpiece considering the effect of cutting sequence

Influence of Machining Parameters on Heat Generation During Milling of Aluminum Alloys

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