Analytical Prediction of Chatter Stability in Milling—Part I: General Formulation

Budak, Erhan; Altintaş, Yusuf

doi:10.1115/1.2801317

Cited by 547 publications

(199 citation statements)

References 16 publications

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“…3 2.2. Time-averaged 2DOF chatter stability analysis 10 Budak and Altintas [13] proposed an analytical method for determining chatter stability in milling. They assumed that the structural dynamics of the tool at the cutting location could be described by two linear frequency response functions (G xx , G yy ).…”

Section: Forces and Deflectionsmentioning

confidence: 99%

Fuzzy stability analysis of regenerative chatter in milling

Sims

Manson

Mann

2010

Journal of Sound and Vibration

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During machining, unstable self-excited vibrations known as regenerative chatter can occur, causing excessive tool wear or failure, and a poor surface finish on the machined workpiece.Consequently it is desirable to predict, and hence avoid the onset of this instability. Regenerative chatter is a function of empirical cutting coefficients, and the structural dynamics of the machine-tool system. There can be significant uncertainties in the underlying parameters, so the predicted stability limits do not necessarily agree with those found in practice.In the present study, fuzzy arithmetic techniques are applied to the chatter stability problem. It is first shown that techniques based upon interval arithmetic are not suitable for this problem due to the issue of recursiveness. An implementation of fuzzy arithmetic is then developed based upon the work of Hanss and Klimke. The arithmetic is then applied to two techniques for predicting milling chatter stability: the classical approach of Altintas, and the time-finite element method of Mann. It is shown that for some cases careful programming can reduce the computational effort to acceptable levels. The problem of milling chatter uncertainty is then considered within the framework of Ben-Haim's information-gap theory.It is shown that the presented approach can be used to solve process design problems with robustness to the uncertain parameters. The fuzzy stability bounds are then compared to previously published data, to investigate how uncertainty propagation techniques can offer more insight into the accuracy of chatter predictions.

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Section: Forces and Deflectionsmentioning

confidence: 99%

Fuzzy stability analysis of regenerative chatter in milling

Sims

Manson

Mann

2010

Journal of Sound and Vibration

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“…And then, by means of Fourier transform the stability lobes are calculated using the real and image part of the characteristic equation of the dynamic system. The method has been widely verified [12,18,19], and also is applied to ball-end milling [20], predicting the stability lobes of the dynamic system with non-uniform pitch angle cutter [13,16] as well as with cutter considering helix angle [21][22][23]. In addition, utilizing the method, Kivanc and Budak [24,25] took finite element analysis (FEA) as a tool to obtain modal parameters of the dynamic system and then predicted stability lobes based on these parameters.…”

Section: Introductionmentioning

confidence: 99%

“…One way of the numerical methods computes the DDEs in frequency domain, Minis and Yanushevsky [14] used Floquet's theory and the Fourier series to calculate the milling stability of dynamic system. Altintas and Budak [12,[15][16][17][18] have made great efforts on computing the stability lobes in the frequency domain. The basic idea of their methods to predict stability limit is translating DDEs from time domain to frequency domain using Fourier Transform.…”

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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“…Some of them apply the measured frequency response functions (FRFs) directly, such as the zero-order approximation (ZOA) [3], the multi-frequency solution (MFS) [4] or the extended multi-frequency solution (EMFS) [5]. Other techniques, such as the semidiscretization method [6], the full-discretization method [7], the integration method [8] and their extension by the implicit subspace iteration method [9], the Chebyshev collocation method [10,11], the spectral element method [12] and the temporal finite element analysis [13,14], require fitted modal parameters as input.…”

Section: Introductionmentioning

confidence: 99%

Operational stability prediction in milling based on impact tests

Kiss

Hajdu

Bachrathy

et al. 2018

Mechanical Systems and Signal Processing

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Chatter detection is usually based on the analysis of measured signals captured during cutting processes. These techniques, however, often give ambiguous results close to the stability boundaries, which is a major limitation in industrial applications. In this paper, an experimental chatter detection method is proposed based on the system's response for perturbations during the machining process, and no system parameter identification is required. The proposed method identifies the dominant characteristic multiplier of the periodic dynamical system that models the milling process. The variation of the modulus of the largest characteristic multiplier can also be monitored, the stability boundary can precisely be extrapolated, while the manufacturing parameters are still kept in the chatter-free region. The method is derived in details, and also verified experimentally in laboratory environment.

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Analytical Prediction of Chatter Stability in Milling—Part I: General Formulation

Cited by 547 publications

References 16 publications

Fuzzy stability analysis of regenerative chatter in milling

Fuzzy stability analysis of regenerative chatter in milling

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

Operational stability prediction in milling based on impact tests

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