Effect of vibration assistance on chatter stability in milling

Wan, Shaoke; Jin, Xianyu; Maroju, Naresh Kumar; Hong, Jun

doi:10.1016/j.ijmachtools.2019.103432

Cited by 30 publications

(9 citation statements)

References 26 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…They considered the periodic contact time of the actuator by Fourier Series and used the dynamic orthogonal cutting model in the stability solution. Wan et al [9] reported the first analytical chatter stability of the vibration-assisted milling process using the semi-discrete method. In his study, the vibration was excited along the feed or normal direction from the workpiece side, and the high-frequency tool-workpiece separations changed the time delay dynamically and hence shifted the stability lobes.…”

Section: Introductionmentioning

confidence: 99%

“…As mentioned above, although there are many studies on the cutting force of EUVAM, most of them only focus on the characteristics or performance of EUVAM, lacking mechanism analysis of its change, and cannot reveal the changes of instantaneous chip thickness and dynamic cutting force with cutting conditions. Even if there are a few studies using analytical methods to calculate the undeformed cutting thickness and thus to predict the cutting forces in EUVAM [9]. However, due to the complexity of elliptical ultrasonic vibration, the cutting edges may lose contact with the workpiece at a high frequency during single tooth-passing period.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Z-map based cutting force prediction for elliptical ultrasonic vibration-assisted milling process

Xiao

Han

et al. 2022

Int J Adv Manuf Technol

View full text Add to dashboard Cite

Elliptical ultrasonic vibration-assisted milling (EUVAM) adds high-frequency vibration to conventional milling (CM) to realize high-frequency intermittent milling. It has broad application prospects in the processing of difficultto-cut materials such as titanium alloys, superalloys and hard and brittle materials. To reveal the mechanism of the highly intermittent cutting nature in EUVAM, according to the motion relationship between cutting edge and workpiece and the Z-map model of the workpiece, a method and its algorithm for calculating undeformed cutting thickness and thus the cutting force in EUVAM are proposed. The simulation results show that EUVAM can improve the actual cutting speed when compared with CM, and the proportion of idle cutting time will directly determine the intermittent degree of the milling process. The experiment of EUVAM is performed to verify the correctness of the proposed cutting force model, and the impact of spindle speed on the cutting force in EUVAM is also analyzed.

show abstract

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Z-map based cutting force prediction for elliptical ultrasonic vibration-assisted milling process

Xiao

Han

et al. 2022

Int J Adv Manuf Technol

View full text Add to dashboard Cite

show abstract

“…This method significantly reduced cutting forces and improved the surface quality. Wan [26] investigated the tool-workpiece separation caused by the modified tooltip path with vibration assistance and developed a dynamic model with varying time delay.Due to the complexity of the ultrasonic elliptical vibration that is classified as a two-dimensional motion, the relevant literature is scarce.…”

Section: Introductionmentioning

confidence: 99%

Stability Analysis and Flutter Suppression of Ultrasonic Elliptical Vibration Milling of Ti-6Al-4V Alloy

Zhang

Wang

Niu

et al. 2022

Preprint

View full text Add to dashboard Cite

Ti-6Al-4V alloy is typical aircraft materials to be difficult machined. Ultrasonic elliptical vibration-assisted milling has been proved to greatly enhance machining performance. In ultrasonic elliptical vibration milling(UEVM), the cutting edge moves in 3D space, reducing extrusion friction between the flank and machined surface, and playing an important role in high precision-efficient manufacturing of difficult-to-cut materials. This paper focused on the stability analysis and flutter supression of ultrasonic elliptical vibration milling of Ti-6Al-4V alloy. There are separated and unseparated types of ultrasonic elliptical vibration milling systems, which stability is analyzed in this study by simulating their tool tip motion paths. The essence of the tip and workpiece at high-frequency separation is revealed through analysis of cutter tooth path in UEVM. Next, the coordinate method is used to set up the window function to facilitate the derivation of true instantaneous chip thickness. The dynamic model of UEVM is established to study the system stability and plot its stability prediction lobes diagrams. The effect of machining parameters on the system stability is assessed and discussed in detail. The prediction results show that the stability region and axial depth of cut grow with the increase of feed rate per tooth and decrease of ultrasonic frequency. Among the six groups of ultrasonic amplitude parameters studied, the optimal system's stability corresponds to the ultrasonic amplitudes of 5 and 3μm in the x-and y-directions, respectively. Finally, stability tests of UEVM are performed, which results well match the numerical simulation predictions. This implies that the proposed window function is adequate, the theoretical model is valid, and the predicted stability curve is feasible and reliable.

show abstract

“…Their achievement provides a theoretical foundation and reference for the milling mechanism research. Wan et al [27] studied the effect of vibration assistance on chatter stability in milling process. The results reveal that the vibration assistance does not improve the critical depth of cut, but generates new stability lobes between the original two adjacent lobes corresponding to no vibration assistance.…”

Section: -Introductionmentioning

confidence: 99%

Three dimensional prediction of stability lobes in end milling of thin-walled structures based on tool and workpiece dimensions

2021

View full text Add to dashboard Cite

Nowadays, researchers are very interested to investigate the dynamic behavior of the thin-walled structures during the machining process due to their broad application in aerospace, automotive industries and etc. One of the main problems in machining of thin-walled structures is unstable chatter vibrations, which causes the poor machined surface quality and decreases the system life span. In this regard, the main aim of this paper is to propose a practical method to solve the chatter instability problem during the milling process of thin-walled components. To this end, first the effects of geometrical parameters like workpiece height, thickness, and tool overhang, diameter and their ratios on the chatter stability are investigated. Then three dimensional stability lobe diagrams (SLDs) base on the mentioned parameters are presented for the first time. In which one can implement the mentioned diagrams to switch the unstable machining process to stable one by changing the value of the system parameters. Finally, the results obtained by the experimental test show that the presented three dimensional diagrams can be utilized to avoid chatter instability in the milling process.

show abstract

Effect of vibration assistance on chatter stability in milling

Cited by 30 publications

References 26 publications

Z-map based cutting force prediction for elliptical ultrasonic vibration-assisted milling process

Z-map based cutting force prediction for elliptical ultrasonic vibration-assisted milling process

Stability Analysis and Flutter Suppression of Ultrasonic Elliptical Vibration Milling of Ti-6Al-4V Alloy

Three dimensional prediction of stability lobes in end milling of thin-walled structures based on tool and workpiece dimensions

Contact Info

Product

Resources

About