Machine Tool Chatter and Surface Quality in Milling Processes

Insperger, Tamás; Gradišek, Janez; Kalveram, Martin; ́n, Ga ́bor Ste ́pa; Weinert, Klaus; Govekar, Edvard

doi:10.1115/imece2004-59692

Cited by 12 publications

(9 citation statements)

References 35 publications

Supporting

Mentioning

Contrasting

Unclassified

Order By: Relevance

“…The benchmark examples, which have been well validated by experiments in published literature [25,26,28], are utilized to check the proposed method.…”

Section: Simultaneous Prediction Of Stability and Slementioning

confidence: 99%

“…It is also necessary to develop an approach for accurate yet efficient prediction of the surface location error (SLE) due to cutter vibration. Numerous efforts have been made to calculate the SLE such as the numerical simulation method [23], the frequency domain method [24], the TFEA method [25][26][27], and the harmonic balance method [28]. To the best knowledge of the authors, the TFEA method [25][26][27] is the first and only theoretical approach for simultaneous prediction of milling stability and SLE.…”

Section: Introductionmentioning

confidence: 99%

“…The tool modal parameters in Eq. (6) are[28] conditions are 10% immersion down-milling, D = 8 mm, A',=644X IO*" N/m-, K,=23lXlO^ N/m^ K,,=K,,=O, /,=0.16 mm/tooth, and A'=l and the SLE is calculated for the depth of cut a=0.8 mm. The result is shown inFig.…”

mentioning

confidence: 99%

“…They agree well with Figs. 7(a) and 7(c) of Ref [28]. by using the Simultaneous prediction of stabiiity and SLE for 10% immersion down-milling semidiscretization method for the prediction of the stability lobe diagram and the harmonic balance method for the SLE.…”

mentioning

confidence: 99%

See 3 more Smart Citations

On a Numerical Method for Simultaneous Prediction of Stability and Surface Location Error in Low Radial Immersion Milling

Ding

Zhu

Zhang

et al. 2011

Journal of Dynamic Systems, Measurement, and Control

View full text Add to dashboard Cite

cn •••"This brief proposes a numerical approach for simultaneous prediction of stability lobe diagrams and surface location error in low radial immersion milling based on the direct integration scheme and the precise time-integration method. First, the mathematical model of the milling dynamics considering the regenerative effect is presented in a state space form. With the cutter tooth passing period being divided equally into a flnite number of elements, the response of the system is formulated on the basis of the direct integration scheme. Then, the four involved time-variant items, i.e., the time-periodic coefficient item, system .state item, time delay item, and static force item in the integration terms of the response, are discretized via linear approximations, respectively. The corresponding matrix exponential related functions are all calculated by using the precise time-integration method. After the state transition expression on one small time interval being constructed, an explicit form for the discrete dynamic map of the system on one tooth passing period is established. Thereafter, the milling stability is predicted via Floquet theory and the surface location error is calculated from the fixed point of the dynamic map. The proposed method is verifled by the benchmark theoretical and experimental results in published literature. The high efflciency of the algorithm is also demonstrated.

show abstract

“…The benchmark examples, which have been well validated by experiments in published literature [25,26,28], are utilized to check the proposed method.…”

Section: Simultaneous Prediction Of Stability and Slementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

mentioning

confidence: 99%

mentioning

confidence: 99%

See 2 more Smart Citations

On a Numerical Method for Simultaneous Prediction of Stability and Surface Location Error in Low Radial Immersion Milling

Ding

Zhu

Zhang

et al. 2011

Journal of Dynamic Systems, Measurement, and Control

View full text Add to dashboard Cite

show abstract

“…The geometrical accuracy of the machined surface is influenced by the process parameters as well as tool oscillations. Since surface accuracy is a measure of machining performance, various literatures are devoted to the investigation of surface location error (SLE) for the stable cutting conditions [17][18][19][20][21][22][23]. Bachrathy et al [23] investigated surface properties based on the helical fluted tool model and introduced surface error parameters for the stable (forced) motion of the tool.…”

Section: Introductionmentioning

confidence: 99%

Chaotic vibrations in high-speed milling

Banihasan

Bakhtiari-Nejad

2011

Nonlinear Dyn

View full text Add to dashboard Cite

A large number of literatures are devoted to the stability of the milling process and various control methods for chatter suppression. But chaotic dynamics beyond the stable region has not been considered extensively. Moreover, modeling issues for chaotic motion need more challenge for accurate prediction of its complex dynamical behavior. This paper presents a detailed two-degree-of-freedom mechanics based model for the study of chaotic vibrations in milling. Segmental multiple regenerative effect that is the principle feature of nonlinear vibrations in milling processes besides two state dependent time delays has been considered. Exact geometrical formulation of multiple regenerative effects by considering simultaneously different numbers of delayed tool positions over the cutting zone is presented for the first time. Phase portrait, bifurcation diagram, largest Lyapunov exponent, and surface profile were calculated for a given machine tool and workpiece parameters. The simulation results show positive values of the largest Lyapunov exponent corresponding to the existence of chaos in high-speed milling operations. Also, investigation of

show abstract

Application of interpolation methods for the determination of position-dependent frequency response functions for the simulation of 5-axis milling processes

Wilck

Wirtz

Biermann

et al. 2021

Prod. Eng. Res. Devel.

View full text Add to dashboard Cite

The occurrence of chatter vibrations in 5-axis milling processes is a common problem and can result in part failure, surface defects and increased wear of the cutting tool and the machine tool. In order to prevent process vibrations, machining processes can be optimized by utilizing geometric physically-based simulation systems. Since the modal parameters of the machine tool are dependent on the position of the linear and rotary axes, the dynamic behavior of milling processes can change along the NC path despite constant engagement conditions. In order to model the pose-dependent modal properties at the tool tip, the frequency response functions (FRFs) were measured at different locations of the workspace of the machine tool for various poses of the rotary axis of the spindle. To take the varying compliance within the workspace of a machine tool into account in a geometric physically-based milling process simulation, different interpolation methods for interpolating FRFs or parameter values of oscillator-based compliance models (OPV) were applied. For validation, the resulting models were analyzed and compared to measured data. In OPV interpolation, the individual oscillation modes were interpolated in their respective characteristics based on the oscillator parameters (eigenfrequencies, modal masses and damping values). In FRF interpolation, however, there was no differentiation between the modes, resulting in a wrong interpolation. It can therefore provide good results when only a small shift of the eigenfrequencies is expected, as in case of the analyzed machine tool, with only small movements of the translatory axes.

show abstract

Machine Tool Chatter and Surface Quality in Milling Processes

Cited by 12 publications

References 35 publications

On a Numerical Method for Simultaneous Prediction of Stability and Surface Location Error in Low Radial Immersion Milling

On a Numerical Method for Simultaneous Prediction of Stability and Surface Location Error in Low Radial Immersion Milling

Chaotic vibrations in high-speed milling

Application of interpolation methods for the determination of position-dependent frequency response functions for the simulation of 5-axis milling processes

Contact Info

Product

Resources

About