Internal Energy Based Analysis on Mechanism of Spindle Speed Variation for Regenerative Chatter Control

Abstract

Among machining chatter control methods, spindle speed variation (SSV) method is certified as a feasible and effective way: machining chatter can be suppressed by continuously and periodically fluctuating the spindle speed of the machine tool. Although with its substantial value, the SSV method has not yet gained enough acceptance in the industrial machining applications. One of the reasons is the inadequacy of theoretical and practical study on the mechanism of the SSV method for machining chatter suppression. In this paper the mechanism of the SSV method for chatter suppression is revealed by means of internal energy analysis. The theoretical analysis is based on a nonlinear delay differential equation (NLDDE) as the model of regenerative machining chatter. This approach can provide more practical and feasible analytical results than small perturbative approaches. The analytical results demonstrate the machining stability increment of SSV cutting in the mathematical and physical sense, and provide practical suggestions for selection of SSV cutting parameters. Numerical simulations and experimental SSV cutting testing outcomes have coincidence with the analytical results.

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“…Globalization and the far reach of the Internet mean that soft computing and its application are emerging for communications, biology, medicine, the humanities, management sciences, and similar fields. (Hsiao et al, 2005a,b,c,d,e;Chen et al, 2005aChen et al, ,b, 2006aChen et al, ,b,c, 2007aChen et al, ,b,c,d,e,f, 2008aChen et al, ,b,c,d,e, 2009aChen et al, ,b,c,d,e,f, 2010aChen et al, ,b,c,d,e,f,g,h, 2011aChen et al, ,b,c,d,e,f, g,h, 2012aChen, 2006Chen, , 2009aChen, ,b, 2010aChen, ,b, 2011aChen, ,b,c,d,e,f,g,h,i, 2012aHsieh et al, 2006;Tsai et al, 2008;Yang et al, 2008a,b;Yeh et al, 2008;Lin et al, 2009a,b;2011a,b;2012a,b;Chen and Chen, 2010a,b;Chen and Saif, 2010;Chiang et al, 2010;Lee, 2010;Lee et al, 2010aLee et al, ,b, 2011aLi et al, 2010;Chen, 2010, 2012;Liu et al, 2010aLiu et al, ,b, 2011aLiu et al, ,b, 2012aShih et al, 2010aShih et al, ,b,c, 2011aSolihin et al, 2010;Zhang et al, 2010aZhang et al, ,b, 2011aZhao 2010aZhao ,b, 2011aAbd-Alla et al, 2011;Ahmadian and Azizi, 2011;Chen and Huang, 2011;C...…”

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Disturbance of the Regenerative Effect by Use of Milling Tools Modified with Asymmetric Dynamic Properties

“…Typical examples are geometrical features such as the constant and variable helix angles [18][19][20][21][22], inequalities [23][24][25] or serrated [26][27][28], set-back cutting edges [29] or structured tools [5,30]. A variation of the spindle speed and thus of the excitation frequency modulates the engagement specific wavelength and disturbs the regenerative effect [31][32][33]. This stabilizing strategy can also be combined with e.g., the use of variable pitch cutters [34].…”