Determination of the stability lobes with multi-delays considering cutter’s helix angle effect for machining process

Guo, Qiang; Sun, Yuwen; Jiang, Yan; Yan, Yanyan; Ming, Pingmei

doi:10.1177/0954405415623480

Cited by 15 publications

(18 citation statements)

References 46 publications

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“…In those models, regeneration process effect and damping process were also integrated to increase model precision. [5][6][7] As we explained, stability analysis begins with modeling of the dynamic of the machining process via mathematic equations. Such studies are accompanied with analytical prediction of the cutting process parameters such as cutting forces or workpiece vibrations in time domain.…”

Section: Introductionmentioning

confidence: 99%

Analytical and experimental stability analysis of AU4G1 thin-walled tubular workpieces in turning process

Sahraoui

Mehdi

Ben-Jaber

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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The development of the manufacturing-based industries is principally due to the improvement of various machining operations. Experimental studies are important in researches, and their results are also considered useful by the manufacturing industries with their aim to increase quality and productivity. Turning is one of the principal machining processes, and it has been studied since the 20th century in order to prevent machining problems. Chatter or self-excited vibrations represent an important problem and generate the most negative effects on the machined workpiece. To study this cutting process problem, various models were developed to predict stable and unstable cutting conditions. Stability analysis using lobes diagrams became useful to classify stable and unstable conditions. The purpose of this study is to analyze a turning process stability using an analytical model, with three degrees of freedoms, supported and validated with experimental tests results during roughing operations conducted on AU4G1 thin-walled tubular workpieces. The effects of the tubular workpiece thickness, the feed rate and the tool rake angle on the machining process stability will be presented. In addition, the effect of an additional structural damping, mounted inside the tubular workpiece, on the machining process stability will be also studied. It is found that the machining stability process is affected by the tubular workpiece thickness, the feed rate and the tool rake angle. The additional structural damping increases the stability of the machining process and reduces considerably the workpiece vibrations amplitudes. The experimental results highlight that the dynamic behavior of turning process is governed by large radial deformations of the thin-walled workpieces. The influence of this behavior on the stability of the machining process is assumed to be preponderant.

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Section: Introductionmentioning

confidence: 99%

Analytical and experimental stability analysis of AU4G1 thin-walled tubular workpieces in turning process

Sahraoui

Mehdi

Ben-Jaber

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…1 The milling size between 1 mm and 1 mm as well as the radius of the cutter less than 0.5 mm define this kind of machining process. 2 Therefore, the studies including cutting forces prediction, 3,4 tool deflection, 5 stability prediction, [6][7][8] and surface finishing, 9 and so on about the micro-milling process have become topics of interest.…”

Section: Introductionmentioning

confidence: 99%

An accurate instantaneous uncut chip thickness model combining runout effect in micro-milling using cutters with the non-uniform helix and pitch angles

Guo

Jiang

Yang

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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As a key factor, the accuracy of the instantaneous undeformed thickness model determines the force-predicting precision and further affects workpiece machining precision in the micro-milling process. The runout with five parameters affects the machining process more significantly compared with macro-milling. Furthermore, modern industry uses cutters with non-uniform pitch and helix angles more and more common for their excellent properties. In this article, an instantaneous undeformed thickness model is presented regarding cutter runout, variable pitch, and helix angles in the micro-milling process. The cutter edge with the cutter runout effect is modeled. Then, the intersecting ellipse between the plane vertical to the spindle axis and the cutter surface which is a cylinder can be gained. Based on this, the points, which are used to remove the material, on the ellipse as well as cutter edges are calculated. The true trochoid trajectory for each cutting point along the tool path is built. Finally, the instantaneous undeformed thickness values are computed using a numerical algorithm. In addition, this article analyzes runout parameters’ effects on the instantaneous undeformed thickness values. After that, helix and pitch angles’ effects on the instantaneous undeformed thickness are studied. Ultimately, the last section verifies the correctness and validity of the instantaneous undeformed thickness model based on the experiment conducted in the literature.

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“…So, chatter avoidance should better be taken into account at the process planning stage, as seen in the literature. [1][2][3][4][5][6] Process damping which is always ignored in the literature on chatter stability analysis affects the chatter stability significantly, especially in machining of some hard-to-machine aerospace materials such as titanium and nickel super alloys where low cutting speeds must be satisfied.…”

Section: Introductionmentioning

confidence: 99%

An improved semi-analytical approach for modeling of process damping in orthogonal cutting considering cutting edge radius

Cao

Zhang

Huang

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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Process damping generated between the tool flank face and the wavy finish workpiece surface has a non-negligible effect on cutting dynamics and chatter stability, especially at low cutting speeds, resulting in higher stability limits. In modeling of process damping, the calculation of extruded volume is one of the most critical challenges, especially in machining with honed tools due to the complex and time-variable contact condition between the arc cutting edge and the finite amplitude wave surface. In this study, a semi-analytical method with high computational efficiency is proposed to calculate the extruded volume in cutting with honed tools. Based on this method, we construct the stability lobes under the condition of finite vibration amplitude accurately and efficiently, which overcomes the limitation of analytical methods based on the assumption of small amplitude vibrations and the low computational efficiency of numerical method. The predicted cutting stability is verified against both the experimental results and the time-domain simulation results.

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Determination of the stability lobes with multi-delays considering cutter’s helix angle effect for machining process

Cited by 15 publications

References 46 publications

Analytical and experimental stability analysis of AU4G1 thin-walled tubular workpieces in turning process

Analytical and experimental stability analysis of AU4G1 thin-walled tubular workpieces in turning process

An accurate instantaneous uncut chip thickness model combining runout effect in micro-milling using cutters with the non-uniform helix and pitch angles

An improved semi-analytical approach for modeling of process damping in orthogonal cutting considering cutting edge radius

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