A Contribution to Improve the Accuracy of Chatter Prediction in Machine Tools Using the Stability Lobe Diagram

Santos, Raphael Galdino dos; Coelho, Reginaldo Teixeira

doi:10.1115/1.4025514

Cited by 22 publications

(3 citation statements)

References 29 publications

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“…In their study, they referred to the fast Fourier transform (FFT) result of the sensing signals; they examined and modified the cutting parameters, on the basis of the result, to suppress the milling chatter. Santos et al [36] considered the activation of spindle electronic control to improve the accuracy of the stability lobe diagram (SLD). The SLD was used to select the appropriate spindle speed and depth of cut to avoid any chatter phenomenon during milling.…”

Section: Related Workmentioning

confidence: 99%

Integrated Design of Spindle Speed Modulation and Cutting Vibration Suppression Controls Using Disturbance Observer for Thread Milling

Yeh

Chen

2021

Materials

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In thread milling, there exists a trade-off between thread manufacturing efficiency and thread quality. In this study, an integrated design of spindle speed modulation (SSM) and cutting vibration suppression (CVS) controls using a disturbance observer were developed to simultaneously ensure superior quality and high manufacturing efficiency. The proposed integrated design not only controls the cutting torque while suppressing cutting vibrations but also ensures cost-effectiveness and mitigates the installation problems prevalent in existing sensor-based methods. The SSM control uses a disturbance observer to estimate the cutting torque required on the spindle during thread milling. The estimated cutting torque is used as a feedback signal so that the SSM control can modulate the spindle speed to make the cutting torque achieve a preset torque command. To further avoid cutting vibrations in thread milling, the CVS control analyzes the estimated cutting torque, detects the occurrence of cutting vibrations, and then adjusts the torque command of the SSM control to suppress the cutting vibrations. In this study, thread milling experiments were performed on a computer numerical control milling machine using the workpiece with stacked materials. The feasibility and performance of the proposed integrated design were validated by experiments.

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Section: Related Workmentioning

confidence: 99%

Integrated Design of Spindle Speed Modulation and Cutting Vibration Suppression Controls Using Disturbance Observer for Thread Milling

Yeh

Chen

2021

Materials

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“…Raphael and Reginaldo 17 investigated the methods of identifying the correct position of the spindle by the electronic transducers. Gao and Meng, Ozturk et al, and Erturk et al 18-20 investigated the different design parameters such as the span of the bearings and the tool overhang effect over the responses at the tool-tip. Lin and Tu, Jiang and Zheng, and Peng et al 21-23 introduced various novel methods to estimate the dynamic and thermal characteristics of the high-speed spindles at different machining conditions.…”

Section: Introductionmentioning

confidence: 99%

Investigation of chatter prediction in end milling using morphological studies on aluminum alloy (Al6061)

Shaik

Mutra

Galal

et al. 2022

Noise & Vibration Worldwide

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Future machine tools have to be highly powerful systems to maintain the needed intellectual performance and stability. The machine tool systems such as Spindle/Tool-holder/Tool assembly are necessary to be optimized for their functionality or cutting performance to meet the productivity and accessibility requirements of the user. Prediction of the dynamic behavior at the spindle tool-tip is, therefore, an important criterion for assessing the machining stability of a machine tool at the design stage. In commercial practice, the machine tool system is extensively influenced by the dynamic rigidity of the spindle system. In this work, a realistic dynamic high-speed spindle/milling tool holder/tool system model is elaborated based on rotor dynamics predictions. Using the finite element modeling with the Timoshenko beam theory, the frequency response at the tool-tip has arrived initially. Further, the numerical model is validated with 3D ANSYS and experimental modal testing. The theoretical stability lobe diagram (SLD) depends on the stiffness and damping properties of the cutting tool and distinguishes the stable and unstable cutting conditions. The mechanism of chatter formation is investigated experimentally during the end milling of Aluminum alloy (Al6061) by two different techniques. Experimental cutting tests are conducted at different depths of cuts, the corresponding vibration signals and cutting samples are examined using the Scanning electronic microscope (SEM) and optical microscope. These studies provide a detailed investigation to predict the stable and unstable cutting zones at different machining conditions.

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“…The main problem to the implementation of high-speed machining of flexible parts or/and cutting tools is an unstable machining condition, known as chatter [11,15,17,20]. Chatter is caused by regeneration of waviness, or the overcutting of the surface left by one tooth of the vibrating cutter by subsequent teeth [9], and can affect the machined surface of the part or increase considerably the tool wear.…”

mentioning

confidence: 99%

On the use of structural dynamics in virtual manufacturing

Vásquez

2014

Int J Interact Des Manuf

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This paper addresses the use of structural dynamics concepts applied to virtual manufacturing. A review of vibration fundamentals is done using a single degree of freedom system. Then, a lab procedure to experimentally determine the frequency response functions and vibration modes of a steel beam by modal fitting is explained. An introduction to receptance coupling substructure analysis is then provided, using an example with two single-degree-of-freedom systems, which are assembled through a flexible coupling. Finally, milling dynamics concepts are introduced, and the stability lobe diagram for an up milling condition is developed. This work provides an explanation of how to use structural dynamics to select cutting parameters that will provide an optimized performance of a milling machine, allowing to maximize profit of the productive process.

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A Contribution to Improve the Accuracy of Chatter Prediction in Machine Tools Using the Stability Lobe Diagram

Cited by 22 publications

References 29 publications

Integrated Design of Spindle Speed Modulation and Cutting Vibration Suppression Controls Using Disturbance Observer for Thread Milling

Integrated Design of Spindle Speed Modulation and Cutting Vibration Suppression Controls Using Disturbance Observer for Thread Milling

Investigation of chatter prediction in end milling using morphological studies on aluminum alloy (Al6061)

On the use of structural dynamics in virtual manufacturing

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