Chatter control and stability analysis of a cantilever boring bar under regenerative cutting conditions

Pratt, Jon R.; Nayfeh, Ali H.

doi:10.1098/rsta.2000.0754

Cited by 78 publications

(62 citation statements)

References 35 publications

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“…Increasing the damping can be achieved by passive [5,6], semi-active [7][8][9] or fully active [10][11][12] means. Another seemingly elegant method is to attempt to break up the mechanism of regenerative chatter by rapidly varying the spindle speed [13,14].…”

Section: Introductionmentioning

confidence: 99%

Analytical prediction of chatter stability for variable pitch and variable helix milling tools

Sims

Mann

Huyanan

2008

Journal of Sound and Vibration

177

120

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Regenerative chatter is a self-excited vibration that can occur during milling and other machining processes. It leads to a poor surface finish, premature tool wear, and potential damage to the machine or tool. Variable pitch and variable helix milling tools have been previously proposed to avoid the onset of regenerative chatter. Although variable pitch tools have been considered in some detail in previous research, this has generally focussed on behaviour at high radial immersions. In contrast there has been very little work focussed on predicting the stability of variable helix tools. In the present study, three solution processes are proposed for predicting the stability of variable pitch or helix milling tools.The first is a semi-discretisation formulation that performs spatial and temporal discretisation of the tool. Unlike previously published methods this can predict the stability of variable pitch or variable helix tools, at low or high radial immersions.The second is a time-averaged semi-discretisation formulation that assumes time-averaged cutting force coefficients. Unlike previous work, this can predict stability of variable helix tools at high radial immersion.The third is a temporal-finite element formulation that can predict the stability of variable pitch tools with a constant uniform helix angle, at low radial immersion.

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Section: Introductionmentioning

confidence: 99%

Analytical prediction of chatter stability for variable pitch and variable helix milling tools

Sims

Mann

Huyanan

2008

Journal of Sound and Vibration

177

120

View full text Add to dashboard Cite

show abstract

“…The resonant phenomena predicted by the analysis will also be analyzed and reported as appropriate. A new programme of research on the use of the results in this paper for the real-time control of the cutting process is under consideration, and this relates to the recent work of Pratt and Nayfeh [40] on chatter control and stability analysis of a cantilever boring bar under regenerative cutting conditions. It is also intended that the work of this paper could be used to provide a map of stable cutting parameters for workshop use in the manual setting-up of machine-tools.…”

Section: Discussionmentioning

confidence: 99%

Approximate Analytical Solutions for Primary Chatter in the Non-Linear Metal Cutting Model

Warmiński

Litak

Cartmell³

et al. 2003

Journal of Sound and Vibration

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This paper considers an accepted model of the metal cutting process dynamics in the context of an approximate analysis of the resulting non-linear differential equations of motion. The process model is based upon the established mechanics of orthogonal cutting and results in a pair of non-linear ordinary differential equations which are then restated in a form suitable for approximate analytical solution. The chosen solution technique is the perturbation method of multiple time scales and approximate closed-form solutions are generated for the most important non-resonant case. Numerical data are then substituted into the analytical solutions and key results are obtained and presented. Some comparisons between the exact numerical calculations for the forces involved and their reduced and simplified analytical counterparts are given. It is shown that there is almost no discernible difference between the two thus confirming the validity of the excitation functions adopted in the analysis for the data sets used, these being chosen to represent a real orthogonal cutting process. In an attempt to provide guidance for the selection of technological parameters for the avoidance of primary chatter, this paper determines for the first time the stability regions in terms of the depth of cut and the cutting speed co-ordinates. #

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“…The intended application of the vibration control system is the suppression of undesirable chatter vibrations during milling of a flexible workpiece. Similar solutions have been developed for milling machine structures by Chung et al (1997) and for other machining applications by Pratt and Nayfeh (2001), but the problem of milling workpiece chatter remains open.…”

Section: Introductionmentioning

confidence: 99%

“…Virtual vibration absorbers have been considered for chatter avoidance in turning by Pratt and Nayfeh (2001). They may offer superior performance than the skyhook approach, but to date it appears that no work has been done to directly compare performance for chatter avoidance applications.…”

Section: Introductionmentioning

confidence: 99%

Vibration Control Strategies for Proof-mass Actuators

Huyanan

Sims

2007

Journal of Vibration and Control

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Proof-mass actuators have been considered for a broad range of structural vibration control problems, from the seismic protection of tall buildings, to the improvement of metal machining productivity by increasing the stability of self-excited vibrations known as chatter. In general this broad range of potential applications means that a variety of controllers have been proposed, without drawing direct comparisons with other controller designs that have been considered for different applications.This article takes three controllers that are potentially suitable for the machining chatter problem: direct velocity feedback, tuned-mass-damper control (or vibration absorber control), and active-tuned-mass-damper control (or active vibration absorber control). These control strategies are restated within the more general framework of Virtual Passive Control. Their performance is first compared using root locus techniques, with a model based upon experimental data that includes the low frequency dynamics of the proof mass. The frequency response of the test structure is then illustrated under open and closed-loop conditions. The application of the control strategies to avoid machine-tool chatter vibrations is then discussed, without going into detail on the underlying physical mechanisms of chatter. It is concluded that virtual passive absorber control is more straightforward to implement than virtual skyhook damping, and may be better suited to the problem of machining chatter.

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Chatter control and stability analysis of a cantilever boring bar under regenerative cutting conditions

Cited by 78 publications

References 35 publications

Analytical prediction of chatter stability for variable pitch and variable helix milling tools

Analytical prediction of chatter stability for variable pitch and variable helix milling tools

Approximate Analytical Solutions for Primary Chatter in the Non-Linear Metal Cutting Model

Vibration Control Strategies for Proof-mass Actuators

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