Piezoelectric active control for workpiece chatter reduction during milling

Sims, Neil D.; Zhang, Yuanming

doi:10.1117/12.538761

Cited by 9 publications

(5 citation statements)

References 11 publications

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“…However, frequently these solutions are neither cheap nor flexible. Another solution is the use of actuators to compensate online the deformation and vibration of the part [7], although the mounting and dismounting of the actuator means adding operations for the machinist. Also, the actuator starts working once the harm is done.…”

Section: Introductionmentioning

confidence: 99%

Chatter avoidance in the milling of thin floors with bull-nose end mills: Model and stability diagrams

Campa

Lacalle

Celaya

2011

International Journal of Machine Tools and Manufacture

120

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The milling of thin parts is a high added value operation where the machinist has to face the chatter problem. The study of the stability of these operations is a complex task due to the changing modal parameters as the part losses mass during the machining and the complex shape of the tools that are used. The present work proposes a methodology for chatter avoidance in the milling of flexible thin floors with a bull-nose end mill. First, a stability model for the milling of compliant systems in the tool axis direction with bullnose end mills is presented. The contribution is the averaging method used to be able to use a linear model to predict the stability of the operation. Then, the procedure for the calculation of stability diagrams for the milling of thin floors is presented. The method is based on the estimation of the modal parameters of the part and the corresponding stability lobes during the machining. As in thin floor milling the depth of cut is already defined by the floor thickness previous to milling, it is proposed the use of stability diagrams that relate the tool position along the tool-path with the spindle speed. Hence, the sequence of spindle speeds that the tool must have during the milling can be selected. Finally, this methodology has been validated by means of experimental tests.

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Section: Introductionmentioning

confidence: 99%

Chatter avoidance in the milling of thin floors with bull-nose end mills: Model and stability diagrams

Campa

Lacalle

Celaya

2011

International Journal of Machine Tools and Manufacture

120

View full text Add to dashboard Cite

show abstract

“…Increasing the damping can be achieved by passive [5,6], semi-active [7][8][9] or fully active [10][11][12] means. Another seemingly elegant method is to attempt to break up the mechanism of regenerative chatter by rapidly varying the spindle speed [13,14].…”

Section: Introductionmentioning

confidence: 99%

Analytical prediction of chatter stability for variable pitch and variable helix milling tools

Sims

Mann

Huyanan

2008

Journal of Sound and Vibration

177

120

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Regenerative chatter is a self-excited vibration that can occur during milling and other machining processes. It leads to a poor surface finish, premature tool wear, and potential damage to the machine or tool. Variable pitch and variable helix milling tools have been previously proposed to avoid the onset of regenerative chatter. Although variable pitch tools have been considered in some detail in previous research, this has generally focussed on behaviour at high radial immersions. In contrast there has been very little work focussed on predicting the stability of variable helix tools. In the present study, three solution processes are proposed for predicting the stability of variable pitch or helix milling tools.The first is a semi-discretisation formulation that performs spatial and temporal discretisation of the tool. Unlike previously published methods this can predict the stability of variable pitch or variable helix tools, at low or high radial immersions.The second is a time-averaged semi-discretisation formulation that assumes time-averaged cutting force coefficients. Unlike previous work, this can predict stability of variable helix tools at high radial immersion.The third is a temporal-finite element formulation that can predict the stability of variable pitch tools with a constant uniform helix angle, at low radial immersion.

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“…To solve this problem, there are solutions based on intelligent devices: fixtures, actuators for active damping, etc. [1,2]. Smith and Dvorak proposed the use of a flat end mill for the floor and a ball end mill for the fillet radius milling [3].…”

Section: Introductionmentioning

confidence: 99%

Critical Thickness and Dynamic Stiffness for Chatter Avoidance in Thin Floors Milling

Campa

Lacalle

Urbicain

et al. 2011

AMR

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A common problem in the aeronautical industry is the chatter vibration due to the lack of dynamic stiffness in the milling of thin walls and thin floors. The present work proposes a method for chatter avoidance in the milling of flexible thin floors with a bull nose end mill. It allows the calculation of the thickness previous to finish milling or the minimum dynamic stiffness that the floor must have to avoid the chatter vibration appearance. To obtain these values, the stability model algorithm has been inverted to estimate the thickness or the dynamic stiffness required in a floor to allow a stable milling. This methodology has been validated satisfactorily in several experimental tests.

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Piezoelectric active control for workpiece chatter reduction during milling

Cited by 9 publications

References 11 publications

Chatter avoidance in the milling of thin floors with bull-nose end mills: Model and stability diagrams

Chatter avoidance in the milling of thin floors with bull-nose end mills: Model and stability diagrams

Analytical prediction of chatter stability for variable pitch and variable helix milling tools

Critical Thickness and Dynamic Stiffness for Chatter Avoidance in Thin Floors Milling

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