Prediction of workpiece dynamics and its effects on chatter stability in milling

Budak, Erhan; Tunç, Lütfi; Alan, Salih; Özgüven, H. Nevzat

doi:10.1016/j.cirp.2012.03.144

Cited by 167 publications

(46 citation statements)

References 10 publications

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“…Hence, the spindle speed providing the same stable cutting depth shifts depending on the varying natural frequency. A similar case was studied in machining of turbine blades [16], where the dynamics of the workpiece vary as it is machined due to changing stiffness and mass as a result of material removal. It was shown that adjusting the spindle speed according to the varying dynamics may decrease process time about 40 %.…”

Section: Variable Spindle Speed Strategy For Improved Stabilitymentioning

confidence: 99%

Investigation of the effects of Stewart platform-type industrial robot on stability of robotic milling

Tunç

Shaw

2016

Int J Adv Manuf Technol

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Mobile machining with industrial robots is proposed as a cost-effective and portable manufacturing alternative to large scale CNC machine tools in large-scale part manufacturing. Robotic milling, one of the widely used mobile machining approaches, involves several technical challenges and distinct characteristics in terms of machining dynamics and stability due to completely different structural build up. In this paper, distinctive effects of Stewart platform-type of hexapod robot on stability of robotic milling is investigated based on characterisation of its structural dynamics, simulation of stability limits and experimental validation. Three aspects are demonstrated: (1) the positiondependent stability diagrams due to the position-dependent dynamics of the hexapod platform, (2) the effects of cross transfer function due to the complex kinematic chain on milling stability and (3) the role of feed rate direction in stability of robotic milling. The conditions for minimised positiondependent stability through appropriate tooling are also illustrated through simulations and experimental verification. The cases where process stability may be governed by either the hexapod robot or the cutting tool modes are discussed and identified through stability analysis. It is shown that the feed rate direction becomes a significant parameter for stability limits in robotic milling. The conditions at which the cross transfer function becomes significant on milling stability are discussed through simulations and experimental results. It is shown that cross transfer functions may significantly affect milling stability especially when the radial depth of cut is less than 50 % of the tool diameter. As one of the important outcomes of this research, it is found that appropriate tooling may decrease the reliance of milling stability on robot position.

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Section: Variable Spindle Speed Strategy For Improved Stabilitymentioning

confidence: 99%

Investigation of the effects of Stewart platform-type industrial robot on stability of robotic milling

Tunç

Shaw

2016

Int J Adv Manuf Technol

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“…A similar problem is discussed in [7], where the authors present a stability prediction method for the workpiece dynamics based on a structural modification technique. They consider a continuous change in the in-process workpiece structure during a machining cycle.…”

Section: Introductionmentioning

confidence: 99%

Dynamics of thin-walled element milling expressed by recurrence analysis

Rusinek

Zaleski

2015

Meccanica

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This paper presents the results of experimental research on the stability of a milling process for producing a thin-walled part made of AL7075 aluminium alloy. The part was machined on a CNC milling machine with a decreasing wall thickness. The acceleration and cutting forces in the process were measured and analyzed to determine stability limit using classical stability diagrams as well as recurrence plots and recurrence quantification analysis.

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“…As a result, cutting-edge CNC systems implement parametric interpolators to accurately create cutting paths without segmentation contour processing. Parametric interpolators manage to overcome problems in real applications such as huge amounts of NC data, unsmooth motion speed, surface accuracy deterioration, machine vibrations [2,3], etc. Although the efficiency of parametric interpolators is at its edge, only a group of CNC units support such functions whilst they are provided as additional modules with independent policy to the rest of the systems.…”

Section: Introductionmentioning

confidence: 99%

Precision Sculptured Surface CNC Machining Using Cutter Location Data

Fountas¹,

Vaxevanidis²,

Stergiou

et al. 2016

KEM

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Abstract. Industrial parts with sculptured surfaces are typically, manufactured with the use of CNC machining technology and CAM software to generate surface tool paths. To assess tool paths computed for 3-and 5-axis machining, the machining error is evaluated in advance referring to the parameter controlling the linearization of high-order curves, as well as the scallop yielded as a function of radial cutting engagement parameter. The two parameters responsible for the machining error are modeled and corresponding cutter location data for tool paths are utilized to compare actual trajectories with theoretical curves on a sculptured surface (SS) assessing thus the deviation when virtual tools are employed to maintain low cost; whilst ensuring high precision cutting. This operation is supported by applying a flexible automation code capable of computing the tool path; extracting its CL data; importing them to the CAD part and finally projecting them onto the part's surface. For a given tolerance, heights from projected instances are computed for tool paths created by changing the parameters under a cutting strategy, towards the identification of the optimum tool path. To represent a global solution rough machining is also discussed prior to finish machining where the new proposals are mainly applied.

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Prediction of workpiece dynamics and its effects on chatter stability in milling

Cited by 167 publications

References 10 publications

Investigation of the effects of Stewart platform-type industrial robot on stability of robotic milling

Investigation of the effects of Stewart platform-type industrial robot on stability of robotic milling

Dynamics of thin-walled element milling expressed by recurrence analysis

Precision Sculptured Surface CNC Machining Using Cutter Location Data

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