Stability of milling processes with continuous spindle speed variation: Analysis in the frequency and time domains, and experimental correlation

Zatarain, Mikel; Bediaga, Iñigo; Muñoa, Jokin; Lizarralde, Rafael

doi:10.1016/j.cirp.2008.03.067

Cited by 120 publications

(62 citation statements)

References 18 publications

(28 reference statements)

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“…On the other hand, the variation of the modal parameters must influence the regenerative mechanism, delaying or facilitating the chatter appearance or the chatter stabilization. If spindle speed variation techniques distort the chip thickness regeneration varying the tooth passing frequency with respect to the natural frequency, the variation of the natural frequency with respect to the cutting frequency should have the same effect [44]. Another error comes from ignoring the feed speed.…”

Section: Discussionmentioning

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: Discussionmentioning

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

“…They obtained some improvements for low spindle speeds. Recently, Zatarain et al [32] presented a general method in the frequency domain to solve the problem and show that variable spindle speed can effectively be used to chatter suppression for low cutting speeds. They used the semidiscretization method and time domain simulations to validate their model and confirmed their results by experiments.…”

Section: Introductionmentioning

confidence: 99%

On the stability of high-speed milling with spindle speed variation

Seguy

Insperger

Arnaud

et al. 2009

Int J Adv Manuf Technol

116

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To cite this version:Sébastien Seguy, Tamás Insperger, Lionel Arnaud, Gilles Dessein, Grégoire Peigné. On the stability of high-speed milling with spindle speed variation. International Journal of Advanced Manufacturing Technology, Springer Verlag, 2010, 48 (9-12) Abstract Spindle speed variation is a well-known technique to suppress regenerative machine tool vibrations, but it is usually considered to be effective only for low spindle speeds. In this paper, the effect of spindle speed variation is analyzed in the high-speed domain for spindle speeds corresponding to the first flip (period doubling) and to the first Hopf lobes. The optimal amplitudes and frequencies of the speed modulations are computed using the semidiscretization method. It is shown that period doubling chatter can effectively be suppressed by spindle speed variation, although, the technique is not effective for the quasiperiodic chatter above the Hopf lobe. The results are verified by cutting tests. Some special cases are also discussed where the practical behavior of the system differs from the predicted one in some ways. For these cases, it is pointed out that the concept of stability is understood on the scale of the principal period of the system-that is, the speed modulation period for variable spindle speed machining and the tooth passing period for constant spindle speed machining.

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“…However, most of them were developed with the aim of constructing stability charts for milling processes, such as the analysis of the milling system with runout [25], with variable pitch/helix cutter [26][27][28][29][30], with variable-spindle speed [31][32][33], or with serrated cutter [34,35]. In order to verify the proposed method, two typical milling operations are chosen and considered.…”

Section: Verification Of Methodsmentioning

confidence: 99%

A Method for Stability Analysis of Periodic Delay Differential Equations with Multiple Time-Periodic Delays

Jin

et al. 2017

Mathematical Problems in Engineering

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Delay differential equations (DDEs) are widely utilized as the mathematical models in engineering fields. In this paper, a method is proposed to analyze the stability characteristics of periodic DDEs with multiple time-periodic delays. Stability charts are produced for two typical examples of time-periodic DDEs about milling chatter, including the variable-spindle speed milling system with one-time-periodic delay and variable pitch cutter milling system with multiple delays. The simulations show that the results gained by the proposed method are in close agreement with those existing in the past literature. This indicates the effectiveness of our method in terms of time-periodic DDEs with multiple time-periodic delays. Moreover, for milling processes, the proposed method further provides a generalized algorithm, which possesses a good capability to predict the stability lobes for milling operations with variable pitch cutter or variable-spindle speed.

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Stability of milling processes with continuous spindle speed variation: Analysis in the frequency and time domains, and experimental correlation

Cited by 120 publications

References 18 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

On the stability of high-speed milling with spindle speed variation

A Method for Stability Analysis of Periodic Delay Differential Equations with Multiple Time-Periodic Delays

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