Variable Compliance-related Aspects of Chatter in Turning Thin-walled Tubular Parts

Abstract

Thin tubular parts are often subject to turning process during manufacturing. The increasing compliance of the workpiece, which is associated to tool displacement and to matter removal, can give rise to chatter, leading to poor surface quality or premature machine/tool damage. The present work addresses an experimental case of turning a steel thin-walled tube featuring intense vibrations with variable parameters. Observations of transient records during the pass suggest a strong influence of the matter removal on the eigenfrequencies of the system, while the tool's motion implies strong variation of the modal projection of the cutting force. Another characteristic phenomenon is the intermittency of the vibrations and discontinuous chatter frequency evolution. These phenomena are reproduced and analyzed numerically. By means of a finite element modeling, the part's geometry variation during the pass is taken into account. Finally, a stability analysis is carried out for several states of this evolutive system in order to gather insight into the steady cutting conditions.

Analytical modeling of a thin-walled cylindrical workpiece during the turning process. Stability analysis of a cutting process

“…• Then, for each eigenvalue Λ , using the Eqs. (21), (22) and (24), the following parameters , and are calculated. The final step enables to calculate the period of rotation .…”

“…The experimental set up consists of a part, fixed by a three-jaw chuck to the machine tool spindle, and a set of sensors. This experiment has been partly addressed in [21,22].…”

Pengaruh Proses Pembubutan Muka (Facing) pada Arah Forward dan Backward Terhadap Besarnya Defleksi yang Terjadi serta Daya Permesinan yang Dibutuhkan

“…Gerasimenko, dkk. melakukan penelitian tentang turning thin walled pada tubular part untuk menyelidiki tentang tool displacement dan material removal, yang mempunyai potensi meningkatkan chatter yang berkorelasi dengan surface roughness yang dihasilkan serta potensi kerusakan pada tool [6].…”

Fixture Optimization in Turning Thin-Wall Components

“…Estimating the static and dynamic behavior of tool and workpiece (i.e., relative frequency response functions) is essential in order to obtain the aforementioned results, and this is particularly critical in the case of thin-wall component machining where workpiece behavior changes during machining due to local stiffness and material removal [10][11][12]. In such cases, many authors use the simulation as the best approach to predict and improve the process [13].…”