Chatter stability of orthogonal turn-milling analyzed by complete discretization method

Sun, Tao; Qin, Lufang; Fu, Yucan; Hou, Jun Ming

doi:10.1016/j.precisioneng.2018.10.012

Cited by 18 publications

(7 citation statements)

References 17 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Because of the eccentric characteristic of micro eccentric shaft, the process of machining is very complex, and the machining precision is difficult to guarantee. Turn-milling is suitable for machining micro eccentric shaft, because the radial force during machining is small [1] and the vibration characteristics are greatly improved, compared to turning [2]. However, due to the small scale of micro eccentric shaft, it is difficult to meet the requirements of evaluation length of the traditional surface profile characterization parameters, which makes it difficult to accurately characterize the actual surface quality of micro eccentric shaft.…”

Section: Introductionmentioning

confidence: 99%

Characterization and functional evaluation of surface texture of micro eccentric shaft based on multi-index

Cheng

Pei

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

Micro eccentric shaft has important application in many high-tech fields because of its small specific gravity, material, and energy saving. The machined surface texture has an indispensable influence on the surface integrity and the final functional capability. However, due to the micro scale and weak rigidity, it is difficult to characterize the surface texture and evaluate the functionality by traditional quantitative parameters. In order to comprehensively realize the surface texture characterization and functional analysis, a mathematical model is established to simulate the surface texture machined with different cutting tools. Then the surface microscopic profile and functional performance of the surface texture are analyzed by amplitude distribution function (ADF) and bearing area curve (BAC), and the surface texture is also evaluated by fractal dimension, which can avoid the negative effects of scale and resolution. Furthermore, power spectrum density (PSD) is utilized to analyze the relationship between the process dynamic state and geometrical specification of the surface texture. The validity of experimental results shown that the microscopic height distribution of surface machined by flat end milling cutter tends to be more random and there are more microscopic geometric features than that of the ball end milling cutter. The machined surface obtained by the flat end milling cutter has better load bearing, wear resistance, and liquid retention capability.

show abstract

Section: Introductionmentioning

confidence: 99%

Characterization and functional evaluation of surface texture of micro eccentric shaft based on multi-index

Cheng

Pei

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

show abstract

“…However, simultaneous machining processes are often accompanied by severe chatter problems because of the complex process-machine interaction in the cutter-workpiece system (CWS); therefore, setting the appropriate cutting conditions become significantly more important, compared with that in conventional machining processes. For a stable process planning, stability analysis represented by stability lobe diagrams (SLDs) has been studied in parallel turning [3][4][5][6], parallel milling [7,8], and the turnmilling processes [9,10]. This research direction is essential to comprehend the phenomenon and the behavior of process stability.…”

Section: Introductionmentioning

confidence: 99%

Development of Automatic Chatter Suppression System in Parallel Milling by Real-Time Spindle Speed Control with Observer-Based Chatter Monitoring

Yamato

Nakanishi

Suzuki

et al. 2021

Int. J. Precis. Eng. Manuf.

View full text Add to dashboard Cite

To maximize the potential for high material removal rates in simultaneous processes such as parallel milling, developing strategies for successful chatter suppression/avoidance is an important concern for manufacturers. In this study, the effectiveness of the spindle speed difference method (SDM) for chatter suppression is discussed in a parallel end-milling process where a flexible workpiece is machined by two tools rotating in opposite direction. The process model is developed, considering that the dynamic variation due to the regenerative effect occurs on a plane perpendicular to the tool axis direction. Through the process simulations and the experiments, this study provides informative discussion for comprehending the process behavior. Additionally, a real-time active chatter suppression system with adaptive SDM, where the spindle speed difference is sequentially optimized during the process according to the tracked chatter frequency, is developed by integrating a chatter monitoring system based on sensorless cutting force estimation with sliding discrete Fourier transform. The results show that the developed real-time adaptive system of spindle speed suppresses chatter vibrations more effectively than non-adaptive SDM system; hence, the integrated system can contribute self-optimizing machining systems oriented to Industry 4.0. Keywords Parallel milling • Chatter • Process control • Speed difference method • Disturbance observer Abbreviations a p Axial depth of cut a t Acceleration of table c f Feed per tooth dF t , dF r , dF a Minute cutting force in tool tangential, radial, and axial directions dF x , dF y , dF z Minute cutting force in Cartesian coordinate system F cut Cutting force F stat Non-process-related force including friction and gravity terms F x , F y , F z Cutting force in Cartesian coordinate system g(θ) Unit step function to judge tooth engagement G(iω) Frequency response function G LPF (s) Low-pass filter h Uncut chip thickness I a ref Motor current reference J r Total inertia of motor, coupling, and ball screw k c Chatter lobe number K t Torque coefficient K te , K re , K ae Edge force coefficient in tangential, radial, and axial directions K tc , K rc , K ac Cutting force coefficients in tangential, radial, and axial directions

show abstract

“…The discretization method has been widely investigated and applied as an interesting and efficient time domain method [12][13][14][15][16][17][18][19][20][21][22][23][24][25][26][27][28][29][30]. By equally discretizing the time period and approximating the delayed term with different polynomials, the zeroth-order and first-order semi-discretization methods ( ZSDM and FSDM ) were proposed by Insperger and Stepan, respectively [12,13].…”

Section: Introductionmentioning

confidence: 99%

“…In order to completely discretize all terms of the DDE including the delayed, time domain, differential, and parameters terms, Li et al [27] presented a complete discretization scheme (CDS) by Euler's method, and the results showed that the CDS had higher efficiency when compared with SDM and FDM. The CDS was successfully applied to predict the chatter stability of turn-milling operations [28]. Xie [29] improved the accuracy and efficiency of the CDS by approximating the time periodic coefficient matrices by way of linear interpolation.…”

Section: Introductionmentioning

confidence: 99%

Milling stability prediction based on the hybrid interpolation scheme of the Newton and Lagrange polynomials

Xia

Wan

Luo

et al. 2021

Int J Adv Manuf Technol

View full text Add to dashboard Cite

The stability lobe diagram (SLD) is commonly used to determine the suitable cutting parameters of the machining system in order to achieve a chatter-free machining process. An improved full discretization method (FDM) is proposed to predict the SLD based on the hybrid interpolation scheme of the Newton and Lagrange polynomials. In order to solve the SLD, a thirdorder Newton polynomial is employed to interpolate the state term of the physical space equation of the system. Meanwhile, to investigate the influence of the interpolation order on predicting the SLD, the delayed term is estimated using the Lagrange polynomials of orders one to four successively. Subsequently, after constructing the transition matrix, a series of calculation for the stability prediction are carried out by applying Floquet theory. The calculated results from these proposed methods demonstrate that the FDM with a second-order Lagrange polynomial is optimal, and further has better computational performance compared with some existing discretization methods. Lastly, the influences of the dynamic parameters on chatter stability are analyzed according to the proposed FDM. When the stiffness and damping ratio increase, the limit cutting depth will be enhanced. The increasing natural frequency not only causes an obvious shift of the lobes to the right, but also raises the limit cutting depth to some extent. These theoretical analyses can guide the prediction and improvement of the chatter stability of a machining system.

show abstract

Chatter stability of orthogonal turn-milling analyzed by complete discretization method

Cited by 18 publications

References 17 publications

Characterization and functional evaluation of surface texture of micro eccentric shaft based on multi-index

Characterization and functional evaluation of surface texture of micro eccentric shaft based on multi-index

Development of Automatic Chatter Suppression System in Parallel Milling by Real-Time Spindle Speed Control with Observer-Based Chatter Monitoring

Milling stability prediction based on the hybrid interpolation scheme of the Newton and Lagrange polynomials

Contact Info

Product

Resources

About