Chatter stability and surface location error predictions in milling with mode coupling and process damping

Li, Zhongyun; Jiang, Shanglei; Sun, Yuwen

doi:10.1177/0954405417708225

Cited by 29 publications

(14 citation statements)

References 41 publications

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“…Its main advantages were precise localization in both the time and frequency domain as well as fewer errors in the frequency domain. Li et al (2017aLi et al ( , 2017b predicted a 3-D stability lobe, in finish milling, where regeneration, helix angle, and process damping were reflected to influence the process. The method considered stiffness and dynamic between tool and workpiece.…”

Section: Introductionmentioning

confidence: 99%

A feedback controller for milling chatter vibration control using a new response matrix

Muhammad

Bashir

Hamza

et al. 2021

Journal of Vibration and Control

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A chatter mark is a result of irregular vibration that affects the milling process, which results in poor surface finish, reduced work quality, machine impairment, and high production cost. This work presents an active feedback controller design using a new response matrix to suppress the free vibration in the milling process. The proposed controller considers feed rate, tooth passing frequency, and time-varying dynamic milling force coefficients. A milling experiment verifies the effect of the proposed method. The method provides a reliable way of tackling chatter vibration in an industrial process. The procedure is technically and economically beneficial.

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Section: Introductionmentioning

confidence: 99%

A feedback controller for milling chatter vibration control using a new response matrix

Muhammad

Bashir

Hamza

et al. 2021

Journal of Vibration and Control

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“…To improve the convergence rate and computational accuracy, Niu et al 10 presented a generalized form of the Runge-Kutta method (GRKM) based on a Volterra integral equation of the second kind. Li et al 11 built an extended dynamic milling model including mode coupling and process damping, and proposed a second-order SDM to simultaneously predict the stability lobes diagram and surface location error by solving this extended dynamic model. Yue et al 12 used FMD to predict the stability of the milling process by taking the characteristics of the contact between the tool and the workpiece into consideration.…”

Section: Introductionmentioning

confidence: 99%

Dynamic modeling and stability prediction in milling process of thin-walled workpiece with multiple structural modes

Zhang

Luo

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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Regenerative chatter can easily occur in the milling process of thin-walled workpiece due to the inherently low stiffness. This article aims to predict the stability of thin-walled workpiece in the milling process with a complete dynamic model. First, multiple structural modes of thin-walled workpiece are taken into consideration, and a complete dynamic model of thin-walled workpiece milling system is developed. Then, a numerical integration method is used to achieve the stability lobe diagrams of the milling system and identify the chatter frequency. Besides, the major structural mode, which is responsible for the occurrence of thin-walled workpiece chatter in the milling process, is predicted. A series of milling tests concerning a general cantilever plate are conducted, and the test results agree well with the predicted results, which shows the effectiveness of the proposed method. Finally, the effects of milling tool and structural modes on milling stability are discussed separately, which could provide theoretical basis for the dynamic modeling of thin-walled workpiece in milling process.

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“…In the majority of studies, two-dimensional (2D) and single/multi degrees of freedom (DOF) model with many simplifying suppositions have been applied. 3–12 A number of investigations have focused on the continuous structure for macro-machining operation. 13–16 For micro-machining operation, most of the researchers modeled the tool using classical continuum theory, 17–24 and some few others developed the tool model by applying non-classical continuum theory.…”

Section: Introductionmentioning

confidence: 99%

Optimization of different parameters related to milling tools to maximize the allowable cutting depth for chatter-free machining

Mokhtari

Jalili

Mazidi

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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Determination of optimal parameters of cutting tool is one of the most significant factors in any operation planning of metal elements, especially in micro-milling process. This article presents an optimization procedure, based on genetic algorithms, to optimize some parameters related to micro-milling tool including number of teeth, shank diameter, fluted section diameter, shank length, taper length, and length of fluted section. The aim of this optimization is maximizing the minimum value of cutting depth on the border of stability lobe diagrams, which is called allowable cutting depth, for chatter-free machining. Cutting tool is modeled as a three-dimensional spinning cantilever Timoshenko beam based on strain gradient elasticity theory. Structural nonlinearity, gyroscopic moment, rotary inertia, and velocity-dependent process damping are also considered in the cutting tool model. The values of natural frequency, damping ratio, and material length scale of the micro-milling tool are calculated using a system identification based on genetic algorithm to match the analytical response with recorded experimental vibration signal. Using beam model, the allowable cutting depth is increased in the optimization process for a specific range of spindle speed to avoid the chatter phenomenon. Analytical study of micro-milling process stability is carried out to determine the cost function of the genetic algorithm. A plot of the greatest fitness in each generation is sketched. In addition, stability lobe diagrams before and after optimization process are presented to show the efficiency of the optimized micro-milling tool. In the presented examples, the results of genetic algorithm may lead to design or find a micro-milling tool that its acceptable cutting depth increases up to 1.9313 times.

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Chatter stability and surface location error predictions in milling with mode coupling and process damping

Cited by 29 publications

References 41 publications

A feedback controller for milling chatter vibration control using a new response matrix

A feedback controller for milling chatter vibration control using a new response matrix

Dynamic modeling and stability prediction in milling process of thin-walled workpiece with multiple structural modes

Optimization of different parameters related to milling tools to maximize the allowable cutting depth for chatter-free machining

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