Identification of bearing dynamics under operational conditions for chatter stability prediction in high speed machining operations

Özşahin, Orkun; Budak, Erhan; Özgüven, H. Nevzat

doi:10.1016/j.precisioneng.2015.03.010

Cited by 34 publications

(7 citation statements)

References 26 publications

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“…Since the Generally, the horizontal (x) and normal (y) axes are used to define a machine tool coordinate system (X MT and Y MT ) shown in Figure 2b, and the x and y directional tool point FRFs in the machine tool coordinate system are measured to analyze vibrations in related directions. The direct and cross FRFs at the tool point in x and y directions compose the frequency response function matrix G xy described in Equation (6). However, in real machining process, the feed direction is not always consistent with the x and y axes defined in machine tool coordinate system (X MT and Y MT ).…”

Section: Modal Theory and Matrix Transformationmentioning

confidence: 99%

“…Generally, the stability lobe diagram (SLD) has been proposed to select appropriate chatter-free machining parameters. To plot the SLD, frequency response functions (FRFs) at the tool point should be obtained in advance [4][5][6]. However, since the machine tool spatial structure and the joints contact positions will vary with the movements of the machine tool moving parts, such as the spindle system and worktable, the tool point FRFs are not constant in the machine tool work volume and result in uncertain SLD predictions.…”

Section: Introductionmentioning

confidence: 99%

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Prediction of Tool Point Frequency Response Functions within Machine Tool Work Volume Considering the Position and Feed Direction Dependence

et al. 2020

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A chatter vibration in milling process results in poor surface finish and machining efficiency. To avoid the chatter vibration, the stability lobe diagram (SLD) which is the function of tool point frequency response functions (FRFs) is adopted to predict the chatter-free machining parameters. However, the tool point FRF varies with the changes of machining positions and feed directions within machine tool work volume. Considering this situation, this paper presents a method to predict the position and feed direction-dependent tool point FRF. First, modal parameters of the tool point FRFs obtained at some typical positions and feed directions are identified by the modal theory and matrix transformation method. With the sample information, a back propagation (BP) neural network whose inputs are the position coordinates and feed angle and outputs are the modal parameters can be trained with the aid of the particle swarm optimization (PSO) algorithm. Then, modal parameters corresponding to any position and feed direction can be predicted by the trained BP neural network and used to reorganize the tool point FRFs with the modal fitting technique. A case study was performed on a real vertical machining center to demonstrate the accurate prediction of position and feed direction-dependent tool point FRFs. Furthermore, the position and feed direction-dependent milling stability was researched and origin-symmetric distributions of the limiting axial cutting depths at each machining position were observed.

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Section: Modal Theory and Matrix Transformationmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Prediction of Tool Point Frequency Response Functions within Machine Tool Work Volume Considering the Position and Feed Direction Dependence

et al. 2020

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“…The optimization method was employed to identify dynamic parameters based on hammering test results. Ö zşahin et al 12 identified the dynamic parameters of spindle bearing and tool-tool holder-spindle interface by impact testing at the stable situation. Apart from hammering test, Du and Hong 13 proposed an ultrasonic method to measure the contact stiffness and contact stress distribution at spindle-tool holder interface.…”

Section: Introductionmentioning

confidence: 99%

Theoretical investigation on nonlinear dynamic characteristic of spindle system

Gao

Qin

Wang

et al. 2020

Advanced Composites Letters

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Radial gap will occur at the spindle–tool holder interface when the spindle rotates at high speed. Therefore, the radial gap will lead to the nonlinear stiffness at the spindle–tool holder connection, and it will have effects on dynamic characteristic of spindle system. In this research, classic elastic theory is adopted to evaluate the nonlinear stiffness at spindle–tool holder interface. Dynamic model of spindle system is established considering the nonlinear stiffness at spindle–tool holder interface. The fourth-order Runge–Kutta method is applied to solve dynamic response of the spindle system. On that basis, effects of drawbar force on dynamic characteristic of the system are investigated. Considering the cutting force, effects of rotational speed on dynamic response of cutter tip are also discussed. The numerical results show that the drawbar force has effects on vibration mode of cutter tip. Chaotic motion will not occur within the range concerned in engineering practice. Considering the cutting force, the motion of cutter tip turns to be chaotic. The proper rotational speed and drawbar force should be chosen to ensure a stable cutting according to the response of cutter tip.

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“…Control of cutting tool vibration using a damping pad was studied by [8]. Chatter stability prediction was studied to understand machine tool dynamics under operational conditions [9]. Vibration and tool wear relationship was investigated during end milling by [10,11].…”

Section: Introductionmentioning

confidence: 99%

Experimental Vibration Analysis of Titanium Aluminum Nitride (TiAlN) Coated Milling Cutting Tool Effects on Surface Roughness of AISI 4140 Steel Products

Yıldız

Saruhan

2018

Düzce Üniversitesi Bilim Ve Teknoloji Dergisi

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The vibration response of material removal process in milling has a significant effect on surface roughness of the product with respect to cutting tool coating. Recent requirements for improving of surface roughness have heightened the need for milling with coated cutting tools. The main objective of this study is to experimentally investigate the role of vibration behavior of cutting tool coated with titanium aluminum nitride (TiAlN) on an AISI 4140 alloy steel work piece surface roughness. The vibration data from work piece were recorded for three milling cutting tools with tool diameters of 10, 12, and 16 and for each diameter different coating thicknesses of 0.0, 2.0, 3.0, and 5.0 (microns) were used respectively. Vibration signals of work piece during milling process in two directions were collected and a roughness tester was used to measure the surface roughness of work piece. The results showed that vibration due to cutting tool coating thickness has a significant effect on surface roughness of work piece. It has been observed that the maximum average surface roughness was obtained for 16 tool diameters with coating thickness of 5.0 while the minimum average surface roughness was obtained for 10 mm tool diameters with coating thickness of 3.0. Surface roughness can be improved by reduction sources of vibration by using appropriate cutting tool coating thickness.

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Identification of bearing dynamics under operational conditions for chatter stability prediction in high speed machining operations

Cited by 34 publications

References 26 publications

Prediction of Tool Point Frequency Response Functions within Machine Tool Work Volume Considering the Position and Feed Direction Dependence

Prediction of Tool Point Frequency Response Functions within Machine Tool Work Volume Considering the Position and Feed Direction Dependence

Theoretical investigation on nonlinear dynamic characteristic of spindle system

Experimental Vibration Analysis of Titanium Aluminum Nitride (TiAlN) Coated Milling Cutting Tool Effects on Surface Roughness of AISI 4140 Steel Products

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