Milling Bifurcations: A Review of Literature and Experiment

Abstract

This review paper presents a comprehensive analysis of period-n (i.e., motion that repeats every n tooth periods) bifurcations in milling. Although period-n bifurcations in milling were only first reported experimentally in 1998, multiple researchers have since used both simulation and experiment to study their unique behavior in milling. To complement this work, the authors of this paper completed a three year study to answer the fundamental question “Is all chatter bad?”, where time-domain simulation and experiments were combined to: predict and verify the presence of period-2 to period-15 bifurcations; apply subharmonic (periodic) sampling strategies to the automated identification of bifurcation type; establish the sensitivity of bifurcation behavior to the system dynamics, including natural frequency and damping; and predict and verify surface location error (SLE) and surface roughness under both stable and period-2 bifurcation conditions. These results are summarized. To aid in parameter selection that yields period-n behavior, graphical tools including Poincaré maps, bifurcation diagrams, and stability maps are presented.

Chatter detection in milling processes—a review on signal processing and condition classification

“…According to Kuljanic et al [72], it is identified that chatter is observed from vibration signals in the 3 directions of movement, while Navarro-Devia et al [264] gave experimental data showing that acceleration signals have a different response to cutting parameters and tool condition in each axis. Moreover, models of chatter stability in milling as a multipoint operation (i.e., multiple teeth with interrupted cut) indicate that the dynamic chip thickness is caused by the vibrations in the feed and normal to feed directions, affecting the forces in both directions, as detailed in [3,[265][266][267]. Consequently, the assessment of signals in the three axes increases the detection performance, as shown by Chen et al [178] and Tangjitsitcharoen et al [74] for diverse signal types.…”

“…7 are isolated zones in the SLD where the chatter condition shifts back and forth, and it is associated with the time periodicity. They are mostly dependent on the number of teeth, radial depth and the tool geometry [3,265,[280][281][282][283][284][285] and may occur even with multivariable cutters [286][287][288]. However, it is noted that when using FRF measurements for the calculation of the stability lobes, the results by Otto et al [289] showed that no stable or unstable islands were found because the probability for stability islands decrease for an increasing number of flexible eigenmodes.…”

MaxEnt feature-based reliability model method for real-time detection of early chatter in high-speed milling

“…In practice, the bifurcation is the secondary Hopf bifurcation and Period-N bifurcation commonly [40].…”

Path Interval and Its Relevance to Cutting Force in Ball and Filleted End Milling

“…CNC milling process is being widely used as one of the core manufacturing technologies [7]. Tool path generation can provide manufacturing process information for a milling process, whereas there are a variety of the machining parameters aff ecting surface quality, machining accuracy, manufacturing efficiency, and so on [8][9][10][11].…”