Position-dependent stability analysis of turning with tool and workpiece compliance

Otto, Andreas; Khasawneh, Firas A.; Radons, Günter

doi:10.1007/s00170-015-6929-1

Cited by 29 publications

(15 citation statements)

References 25 publications

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“…The influence of the various cutting positions on the frequency response function and chatter stability was investigated in [16]. Recently, Otto et al [17] extended the number of the mode shapes of Chen and Tsao's compliant model and analyzed the influence of cutting positions on chatter stability theoretically.…”

Section: Introductionmentioning

confidence: 99%

Model-based chatter stability prediction and detection for the turning of a flexible workpiece

Zi-sheng

et al. 2018

Mechanical Systems and Signal Processing

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Machining long slender workpieces still presents a technical challenge on the shop floor due to their low stiffness and damping. Regenerative chatter is a major hindrance in machining processes, reducing the geometric accuracies and dynamic stability of the cutting system. This study has been motivated by the fact that chatter occurrence is generally in relation to the cutting position in straight turning of slender workpieces, which has seldom been investigated comprehensively in literature. In the present paper, a predictive chatter model of turning a tailstock supported slender workpiece considering the cutting position change during machining is explored. Based on linear stability analysis and stiffness distribution at different cutting positions along the workpiece, the effect of the cutting tool movement along the length of the workpiece on chatter stability is studied. As a result, an entire stability chart for a single cutting pass is constructed. Through this stability chart the critical cutting condition and the chatter onset location along the workpiece in a turning operation can be estimated. The difference between the predicted tool locations and the experimental results was within 9% at high speed cutting. Also, on the basis of the predictive model the dynamic behavior during chatter that when chatter arises at some cutting location it will continue for a period of time until another specified location is arrived at, can be inferred. The experimental observation was in good agreement with the theoretical inference. Moreover, it is shown that vibration spectrum is more sensitive to the chatter evolution than the signal variance. Specifically, when the cutting operation transfers from stable to unstable state, the corresponding vibration frequency features a shift from the spindle rotation frequency or its harmonics to the critical chatter frequency that slightly varies during the chatter-lasting period.

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Section: Introductionmentioning

confidence: 99%

Model-based chatter stability prediction and detection for the turning of a flexible workpiece

Zi-sheng

et al. 2018

Mechanical Systems and Signal Processing

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“…If such a workpiece is unsupported with a tailstock, it may in practice bend away from the tool. Otto et al [14] have modelled this tendency using well established theory for the bending of beams, using a fourth order partial differential equation involving parameters such as the modulus of elasticity. Flexibility of both the tool and workpiece leads to increased numbers of degrees of freedom.…”

Section: Resultsmentioning

confidence: 99%

“…If the workpiece is thin enough to be flexible, with a tendency to bend away from the tool, then the modes of vibration of the workpiece become as important as those of the tool. This has become a very recent area of research within chatter theory (Otto et al [14], Khasawneh and Otto [9]) which is not explored in the present paper but is briefly mentioned in the concluding remarks.…”

Section: Introductionmentioning

confidence: 94%

An Integro-Differential Equation with Variable Delay Arising in Machine Tool Vibration

Wang¹,

Gourley²,

Xiao³

2019

SIAM J. Appl. Math.

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We rigorously derive an integro-differential equation as a model for the possible onset of regenerative chatter during a turning process using a lathe. The cut is made parallel to the axis of rotation of the spindle. The model allows the spindle speed to continuously vary with time, which results in the presence of a variable time delay determined from a threshold condition. We present a number of conditions sufficient for the elimination of chatter, these emphasize sufficiently low feed rate or sufficiently high spindle speed. Numerical simulations cast light on the effect of a sinusoidally varying spindle speed, a feature of some modern lathes. Spindle speed variation can cure chatter but does not necessarily do so, and can fail at higher values of the tool feed rate.

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“…They proposed an alternative based on a version of dde23 from Matlab © to analyze chatter cases [55]. Otto et al [56] made an approach to generalize turning cases were verification of their models was made with published experimental data from the literature. In a counterintuitive way, they stated that an increase in the stiffness of the workpiece can destabilize the tool modes producing an undesirable effect in the cutting stiffness and damping.…”

Section: Of 18mentioning

confidence: 99%

Prediction Methods and Experimental Techniques for Chatter Avoidance in Turning Systems: A Review

et al. 2019

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The general trend towards lightweight components and stronger but difficult to machine materials leads to a higher probability of vibrations in machining systems. Amongst them, chatter vibrations are an old enemy for machinists with the most dramatic cases resulting in machine-tool failure, accelerated tool wear and tool breakage or part rejection due to unacceptable surface finish. To avoid vibrations, process designers tend to command conservative parameters limiting productivity. Among the different machining processes, turning is responsible of a great amount of the chip volume removed worldwide. This paper reports some of the main efforts from the scientific literature to predict stability and to avoid chatter with special emphasis on turning systems. There are different techniques and approaches to reduce and to avoid chatter effects. The objective of the paper is to summarize the current state of research in this hot topic, particularly (1) the mechanistic, analytical, and numerical methods for stability prediction in turning; (2) the available techniques for chatter detection and control; (3) the main active and passive techniques.

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Position-dependent stability analysis of turning with tool and workpiece compliance

Cited by 29 publications

References 25 publications

Model-based chatter stability prediction and detection for the turning of a flexible workpiece

Model-based chatter stability prediction and detection for the turning of a flexible workpiece

An Integro-Differential Equation with Variable Delay Arising in Machine Tool Vibration

Prediction Methods and Experimental Techniques for Chatter Avoidance in Turning Systems: A Review

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