Chatter problems in micro- and macrocutting operations, existing models, and influential parameters—a review

Novakov, Tamara; Jackson, Mark J.

doi:10.1007/s00170-009-2213-6

Cited by 21 publications

(3 citation statements)

References 37 publications

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“…The wear effect during the performed cutting trials has not been measured or considered in the discussion for the coated and uncoated end-mill cutters. A summary of the effect and suppression of chatter in micro-machining operations has been presented in [10].…”

Section: Introductionmentioning

confidence: 99%

Effects of the Cutting Tool Edge Radius on the Stability Lobes in Micro-Milling

Afazov

Ratchev

Segal

2011

AMR

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This paper investigates the effects of the cutting tool edge radius on the cutting forces and stability lobes in micro-milling. The investigation is conducted based on recently developed models for prediction of micro-milling cutting forces and stability lobes. The developed models consider the nonlinearities of the micro-milling process, such as nonlinear cutting forces due to cutting velocity dependencies, edge radius effect and run-out presence. A number of finite element analyses (FEA) are performed to obtain the cutting forces in orthogonal cutting which are used for determining the micro-milling cutting forces. The chip morphology obtained for different tool edge radii using FEA is presented. It is observed that at large tool edge radii the influence of the ploughing effect become more significant factor on the chip morphology. The results related to micro-milling cutting forces and stability lobes show that by enlarging the tool edge radius the micro-milling cutting forces increase while the stability limits decrease.

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Section: Introductionmentioning

confidence: 99%

Effects of the Cutting Tool Edge Radius on the Stability Lobes in Micro-Milling

Afazov

Ratchev

Segal

2011

AMR

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“…However, processing vibration seriously affects the stability of cutting processes, and hence machining quality and precision. Kayhan et al compared the machining quality between two components, in which the quality of one component is seriously reduced by chatter vibration [ 1 ]. Novakov et al indicated by experiment that the chatter vibration will reduce the lifetime of cutting tools about 50%–80% [ 2 ].…”

Section: Introductionmentioning

confidence: 99%

A Novel Hybrid Error Criterion-Based Active Control Method for on-Line Milling Vibration Suppression with Piezoelectric Actuators and Sensors

Zhang

Wang

Gao

et al. 2016

Sensors

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Milling vibration is one of the most serious factors affecting machining quality and precision. In this paper a novel hybrid error criterion-based frequency-domain LMS active control method is constructed and used for vibration suppression of milling processes by piezoelectric actuators and sensors, in which only one Fast Fourier Transform (FFT) is used and no Inverse Fast Fourier Transform (IFFT) is involved. The correction formulas are derived by a steepest descent procedure and the control parameters are analyzed and optimized. Then, a novel hybrid error criterion is constructed to improve the adaptability, reliability and anti-interference ability of the constructed control algorithm. Finally, based on piezoelectric actuators and acceleration sensors, a simulation of a spindle and a milling process experiment are presented to verify the proposed method. Besides, a protection program is added in the control flow to enhance the reliability of the control method in applications. The simulation and experiment results indicate that the proposed method is an effective and reliable way for on-line vibration suppression, and the machining quality can be obviously improved.

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“…Chatter in micro-machining process limits tool life, machining quality and tolerances. The chatter theory developed for macro-machining is not proper for analysing micro-machining operation (Novakov and Jackson, 2009). Deburring is a time-consuming thing in machining titanium alloys.…”

Section: Introductionmentioning

confidence: 99%

Experimental study on micro-milling of Ti6Al4V with minimum quantity lubrication

Zheng

Liu

Chen

et al. 2013

IJNM

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The micro-milling of titanium alloy is a challenging task. Minimum quantity lubrication (MQL) is an eco-friendly coolant and low cost method for manufacturing compared with traditional coolant method. This paper studied the micro-milling mechanism of titanium alloy by analysing the tool wear, tool life, cutting vibration, surface finish and burr formation under MQL and dry cutting conditions. Experimental results show that MQL method in micro-milling will significantly improve tool life and reduce material adhesion. In order to study the influence of air fluid on micro-milling process, cutting vibration signal and surface morphology under different air fluid parameters were measured and analysed. Analysis results indicate that the air fluid direction of 180° and 0° aggravate tool vibration and lead to poor surface quality compared with the direction of 270° and 90°. Air pressure also has great influence on tool vibration and burr formation. The burr size under 0.45 MPa is bigger than other air pressures.

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Chatter problems in micro- and macrocutting operations, existing models, and influential parameters—a review

Cited by 21 publications

References 37 publications

Effects of the Cutting Tool Edge Radius on the Stability Lobes in Micro-Milling

Effects of the Cutting Tool Edge Radius on the Stability Lobes in Micro-Milling

A Novel Hybrid Error Criterion-Based Active Control Method for on-Line Milling Vibration Suppression with Piezoelectric Actuators and Sensors

Experimental study on micro-milling of Ti6Al4V with minimum quantity lubrication

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