3D chatter stability of high-speed micromilling by considering nonlinear cutting coefficients, and process damping

Chen, Qidi; Li, Wei; Ren, Yinghui; Zhou, Zhixiong

doi:10.1016/j.jmapro.2020.07.016

Cited by 17 publications

(2 citation statements)

References 25 publications

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“…After the optimization of teeth number, shank diameter, and other important geometries of the micro-tool, the allowable cutting depth for chatter-free machining has been improved. 23 In addition, the dynamic characteristics have great impacts on the micro-milling stability. The vibration energy can be dissipated by the damping, so the tuned mass damper has been employed in chatter mitigation, which exhibits excellent performance by expanding the stable region by 13 times.…”

Section: Introductionmentioning

confidence: 99%

Machinability analysis of micro-milling thin-walled Ti-6Al-4V micro parts under dry, lubrication, and chatter mitigation conditions

Wang

Bai

Cheng

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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Micro-milling technology is an efficient method for machining titanium alloy thin-walled micro parts. However, the machinability of thin-walled microstructures can be greatly affected by chatters due to their weak stiffness, especially in difficult-to-machine materials like titanium alloys. In order to obtain high-quality thin-walled micro parts, a chatter mitigation strategy is presented and its mechanism is analyzed in this paper. The titanium alloy workpiece is submerged into a kind of high-viscosity fluid, which can improve machining stability by increasing the damping of the micro-milling process. The stability lobe diagrams (SLD) are established, and the machinability is analyzed and compared under different machining conditions. The cutting force, surface roughness, micro-tool wear, and dimension accuracy of thin-walled micro parts are selected as the evaluation criteria for the machinability assessment. Well-designed micro-milling experiments are carried out under dry, lubrication, and chatter mitigation conditions using the same cutting process parameters. The results show that the use of cutting fluid can effectively improve machinability under stable cutting processes, but the effect of cutting fluid is weakened under chatter machining. The proposed chatter mitigation strategy can suppress regenerative chatter throughout the micro-milling process for thin-walled micro parts and improve their machinability comprehensively.

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Section: Introductionmentioning

confidence: 99%

Machinability analysis of micro-milling thin-walled Ti-6Al-4V micro parts under dry, lubrication, and chatter mitigation conditions

Wang

Bai

Cheng

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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show abstract

“…Under certain parameters, the stability of the system is destroyed, and chatter occurs. The phenomenon of chatter generated from the machining process is a self-exited vibration between the cutting tool and workpiece [2][3][4], which results in poor surface quality and dimensional accuracy of the workpiece and accelerates the abrasion of the tool [5][6][7][8][9]. Generally, as the final procedure of machining, grinding has significance for the quality of the workpiece [10][11][12].…”

Section: Introductionmentioning

confidence: 99%

Theoretical and Experimental Analysis of Grinding Stability of Beam Workpiece

Yao

2023

Processes

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Grinding chatter is a kind of self-excited vibration in which the grinding system continuously absorbs energy from the grinding machine, increasing the mechanical energy of the system. Grinding chatter can damage the surface of the workpiece and accelerate the abrasion of the grinding wheel. The theoretical analysis of the grinding chatter for the beam surface was launched based on the behavior of a single abrasive grain, whose cutting thickness is a key factor affecting grinding stability. The dynamic grinding force model has been developed, which is the interaction interface between the grinding wheel and the workpiece. In this paper, rail beam grinding was taken as an example. The vibration performance of the rail beam was described with the Timoshenko beam. The characteristics of the frequency domain of the grinding wheel-workpiece system were observed, and the condition of the stability at any position in the longitudinal direction of the beam was gained, which could be quantitatively characterized with the stability limit curve. The grinding experiments of the rail beam surface demonstrated that as chatter developed, the chatter marks could be investigated on the surface of the rail, and the energy of the chatter signal was mainly concentrated around the chatter frequency, which was higher than the natural frequency of the grinding wheel.

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Machinability and cutting force modeling of 7055 aluminum alloy with wide temperature range based on dry cutting

Zhang

Cao

Zhang

et al. 2020

Int J Adv Manuf Technol

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3D chatter stability of high-speed micromilling by considering nonlinear cutting coefficients, and process damping

Cited by 17 publications

References 25 publications

Machinability analysis of micro-milling thin-walled Ti-6Al-4V micro parts under dry, lubrication, and chatter mitigation conditions

Machinability analysis of micro-milling thin-walled Ti-6Al-4V micro parts under dry, lubrication, and chatter mitigation conditions

Theoretical and Experimental Analysis of Grinding Stability of Beam Workpiece

Machinability and cutting force modeling of 7055 aluminum alloy with wide temperature range based on dry cutting

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