Material removal process optimization for milling of flexible workpiece considering machining stability

Luo, Ming; Zhang, D H; Wu, Baohai; Zhou, Xing

doi:10.1177/2041297510393650

Cited by 18 publications

(12 citation statements)

References 13 publications

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“…He also studies stability analysis in milling of thin-walled workpieces with emphasis on the structural effect. 39 Luo et al 40 research material removal process optimization for milling of flexible workpiece considering machining stability. Zaghbani et al 41 use the stability technology on a robotic machining system.…”

Section: Introductionmentioning

confidence: 99%

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

Guo

Sun

Jiang

et al. 2016

Proceedings of the Institution of Mechanical Engineers, Part B:

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As a common phenomenon, chatter is one of the most important factors that inhibit the improvement of productivity and deteriorate the machined surface quality in milling process. In this article, the mathematical model of the dynamic machining process is first constructed with multi-delays, in which the effect of the cutter’s helix angle on the chatter is considered. And a new integral interpolation method is proposed to predict the stability lobes. Based on this method, the mathematical model which is divided into two parts is calculated respectively with an interpolation method and an integration method. Using the Floquet theory, the stability limits of the dynamic milling system for an arbitrary point can thus be precisely predicted. Subsequently, the convergence rate of this integral interpolation method is analyzed. In order to verify the mathematical model, the stability lobes with uniform and variable cutter pitch angle are computed and the results show a good agreement with published experimental data; also one experiment is conducted to validate the proposed model and the method. Simultaneously, the simulation of a stability lobe with non-zero helix angle is also performed and the results validate the fact that the proposed method is capable of predicting stability limits with high accuracy. Finally, the influences of the cutter and process parameters such as helix angle, pitch angle, down-milling or up-milling and radial cutting depth on the milling chatter are analyzed.

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Section: Introductionmentioning

confidence: 99%

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

Guo

Sun

Jiang

et al. 2016

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

show abstract

“…Such studies are accompanied with analytical prediction of the cutting process parameters such as cutting forces or workpiece vibrations in time domain. 8–12…”

Section: Introductionmentioning

confidence: 99%

“…Such studies are accompanied with analytical prediction of the cutting process parameters such as cutting forces or workpiece vibrations in time domain. [8][9][10][11][12] Experimental results represent also an important support and regulator to the theoretical studies. With technological development, many parameters can be measured to clarify various parameters dependency like the influence of the depth of cut and the spindle speed same as the stability analysis theory.…”

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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“…Stability analysis for face milling operations is much more complicated than other cutting process due to the rotation of the cutting tool and the interrupted nature of the cutting process. 3,4 Besides, the directional coefficients (cutting force and the transfer function of chip thickness) vary with the cutting inserts rotating, which makes it more difficult to analyze the stability for face milling operations. 5,6…”

Section: Introductionmentioning

confidence: 99%

Frequency-domain stability lobe prediction for high-speed face milling process under tool–workpiece dynamic interaction

Shi

Liu

Wang

et al. 2016

Proceedings of the Institution of Mechanical Engineers, Part B:

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Self-excited vibrations of the face milling process can result in instability, poor surface finish and machine tool failure. In order to avoid chatter vibrations, this article develops an algorithm for predicting the stability lobes for face milling processes. It considers the factors including radial instantaneous chip thickness, entry and exit angles and the dynamic interaction between cutting tool and workpiece which is often neglected by many researchers. An electronic impact hammer is used to identify the dynamic parameters of the face milling system. Milling experiments have been conducted to validate the predictive capability of the developed algorithm for stability lobes. The results show that the prediction model can estimate the stable and unstable zones for face milling process. This article provides a frequency-domain method for establishing stability lobes which can predict stability zones rapidly. The outcome of this research will bring about methodologies for cost-effective monitoring of face milling processes and maximize the material removal rate.

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Material removal process optimization for milling of flexible workpiece considering machining stability

Cited by 18 publications

References 13 publications

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

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

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

Frequency-domain stability lobe prediction for high-speed face milling process under tool–workpiece dynamic interaction

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