A unified stability prediction method for milling process with multiple delays

Wan, Min; Zhang, Weihong; Dang, Jian-Wei; Yang, Yun

doi:10.1016/j.ijmachtools.2009.09.009

Cited by 126 publications

(90 citation statements)

References 38 publications

(167 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%

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%

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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“…As illustrated in Fig. 7(b), the chatter chart has 5 and 3.5 frequency lobes in the spindle speed interval [8,10] krpm and [11,12] krpm in milling process without cutter run-out.Whereas, when the chatter chart has 10.5 and 6.5 frequency lobeswith run-out. Figure 7(c) shows the critical characteristic values of five unstable machining points and their positions on the unit circle.…”

Section: Example Ii: Experiments Verificationmentioning

confidence: 99%

“…During milling process, chatter vibration is possibly excited by the dynamic interactions between the cutting tool and workpiece [6][7][8][9]. If the current cutting edge removes the material left by the first previous cutting edge, the single regenerative effect of chatter vibration occurs.…”

Section: Introductionmentioning

confidence: 99%

Prediction of stability limit for multi-regenerative chatter in high performance milling

Guo

Sun

Jiang

et al. 2014

Int. J. Dynam. Control

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Chatter is one of the most important factors that inhibit the improvement of productivity and deteriorate the machined surface quality in milling process. In order to obtain good surface quality, classical machining process usually has to take conservative milling parameters. Based on the authors' previous work, this paper presented a new thirdorder discretization method to compute the stability lobes considering multi-regenerative chatter effect. A mathematical model, which is suitable for the dynamic system with non-uniform pitch cutter or cutter run-out, is first established for multi-regenerative chatter. Then, three examples are performed to test the validity of the proposed method. The first example is for the case that the system takes a non-uniform pitch cutter. In the second example, after the modal parameters, run-out parameters and cutting force parameters are gained from experiments, the stability lobes are predicted using the proposed method and subsequently testified by a series of experiments. The third example is for the case of existing cutter run-out. The final computation and experiment results indicate the effectiveness and validity of the proposed method. It is applicable in high performance machining for achieving a good parameter combination.

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“…Other recent activity has also focused on the behaviour at low radial immersion: for example Insperger's semi-discretization approach [5][6][7][8][9]. This concept has more recently been extended to consider variable helix tools [10] and runout [11]. The issue of tool runout was also considered by reference [12].…”

Section: Literature Reviewmentioning

confidence: 99%

The influence of feed rate on process damping in milling: modelling and experiments

Sims

Turner

2011

Proceedings of the Institution of Mechanical Engineers, Part B:

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eprints@whiterose.ac.uk https://eprints.whiterose.ac.uk/ Reuse Unless indicated otherwise, fulltext items are protected by copyright with all rights reserved. The copyright exception in section 29 of the Copyright, Designs and Patents Act 1988 allows the making of a single copy solely for the purpose of non-commercial research or private study within the limits of fair dealing. The publisher or other rights-holder may allow further reproduction and re-use of this version -refer to the White Rose Research Online record for this item. Where records identify the publisher as the copyright holder, users can verify any specific terms of use on the publisher's website. TakedownIf you consider content in White Rose Research Online to be in breach of UK law, please notify us by emailing eprints@whiterose.ac.uk including the URL of the record and the reason for the withdrawal request. DOI: 10.1243/09544054JEM2141Abstract: The performance of milling operations is limited by the onset of unstable self-excited vibrations known as regenerative chatter. Over the past few decades there has been a great deal of research to help predict and explain regenerative chatter. Consequently, high-speed milling operations are now frequently employed, with judicious choice of spindle speeds and depths of cut so as to avoid chatter whilst maintaining high productivity. However, many materials that are increasingly used in aerospace components are difficult to machine at high spindle speeds because of their thermal properties. Examples include titanium and nickel alloys. For these materials, low-speed machining must be employed, and in this regime the role of regenerative chatter is less clearly understood due to the phenomenon of process damping. In the present study, a time domain model of process damping is developed. This model is used to explore the relationship between cutting conditions and the amplitude of chatter vibrations. A qualitative agreement is found between experimental behaviour and the numerical model. In particular, the model predicts a strong relationship between the workpiece feed rate (expressed as a feed per tooth), and the acceptable chatter stability defined by the process damping wavelength. Further work is needed to properly calibrate some of the model parameters.

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A unified stability prediction method for milling process with multiple delays

Cited by 126 publications

References 38 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

Prediction of stability limit for multi-regenerative chatter in high performance milling

The influence of feed rate on process damping in milling: modelling and experiments

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