Analytical prediction of chatter stability for variable pitch and variable helix milling tools

Sims, Neil D.; Mann, Brian P.; Huyanan, S.

doi:10.1016/j.jsv.2008.03.045

Cited by 178 publications

(135 citation statements)

References 30 publications

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“…Some of them apply the measured frequency response functions (FRFs) directly, such as the zero-order approximation (ZOA) [3], the multi-frequency solution (MFS) [4] or the extended multi-frequency solution (EMFS) [5]. Other techniques, such as the semidiscretization method [6], the full-discretization method [7], the integration method [8] and their extension by the implicit subspace iteration method [9], the Chebyshev collocation method [10,11], the spectral element method [12] and the temporal finite element analysis [13,14], require fitted modal parameters as input.…”

Section: Introductionmentioning

confidence: 99%

Operational stability prediction in milling based on impact tests

Kiss

Hajdu

Bachrathy

et al. 2018

Mechanical Systems and Signal Processing

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Chatter detection is usually based on the analysis of measured signals captured during cutting processes. These techniques, however, often give ambiguous results close to the stability boundaries, which is a major limitation in industrial applications. In this paper, an experimental chatter detection method is proposed based on the system's response for perturbations during the machining process, and no system parameter identification is required. The proposed method identifies the dominant characteristic multiplier of the periodic dynamical system that models the milling process. The variation of the modulus of the largest characteristic multiplier can also be monitored, the stability boundary can precisely be extrapolated, while the manufacturing parameters are still kept in the chatter-free region. The method is derived in details, and also verified experimentally in laboratory environment.

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Section: Introductionmentioning

confidence: 99%

Operational stability prediction in milling based on impact tests

Kiss

Hajdu

Bachrathy

et al. 2018

Mechanical Systems and Signal Processing

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“…Milling tools with varying helix angle [14,15,16,17,10] or with wavy cutting edges [18,19] are used to achieve a similar effect by distributing the concentrated time delay even further to continuously varying delays over a given delay-interval. In these cases, the pitch angles are changing continuously along the axial coordinate of the tool, which leads to DDE models with distributed time delays [20].…”

Section: Introductionmentioning

confidence: 99%

Effect of wavy tool path on the stability properties of milling by the implicit subspace iteration method

Tóth

Bachrathy

Stépàn

2016

Int J Adv Manuf Technol

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There are several practical methods to reduce machine tool vibrations that have negative effects especially on the quality of the machined surface. The most intricate vibration is the regenerative one originated in a delay effect of cutting processes. One group of the methods that may be successful in avoiding regenerative vibrations is the appropriate variation of the corresponding time delay. This study presents the stability analysis of milling processes in case of an especially intricate way of varying the delay in time: the radial depth of cut is varied in face milling resulting in a wavy tool path. The combination of the semidiscretization method and the implicit subspace iteration method is introduced to present an efficient way of calculating stability charts that provide conclusions regarding the use of this method in eliminating chatter.Keywords: chatter; wavy tool path; implicit subspace iteration; semi-discretization IntroductionMachine tool chatter has a negative effect on the lifetime of the machine tools and on the quality of the surface finish of the workpiece [1][2][3][4]. This self-excited vibration is originated in the so-called surface regeneration effect [3][4][5]. The mathematical modeling of chatter is rooted in the theory of delay differential equations (DDEs) [6], and the primary cause of instability is the presence of a large time delay in the cutting processes.A constant single point delay appears in the DDE of the commonly used mechanical models of milling processes at constant spindle speed if conventional helical tools with even pitch angles are used. The time delays are proportional to the pitch angles between two neighboring cutting edges, and inversely proportional to the spindle speed.Different tool geometries and operating conditions have been developed in order to improve the stability properties of cutting processes by weakening the negative effect of the inherent time delay by disturbing the concentrated nature of the delayed term in the corresponding equations of motion.In case of milling processes, the concentrated nature of the time delay can be changed to a more disturbed one by introducing uneven pitch angles between the cutting edges [7,8,9,10]. This idea results in multiple discrete time delays in the system, whose number depends on the number of teeth of the tool and the applied pitch angle distribution [11,12,13].Milling tools with varying helix angle [14,15,16,17,10] or with wavy cutting edges [18,19] are used to achieve a similar effect by distributing the concentrated time delay even further to continuously varying delays over a given delay-interval. In these cases, the pitch angles are changing continuously along the axial coordinate of the tool, which leads to DDE models with distributed time delays [20]. In addition to the continuously varying

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“…The most powerful source of chatter is regeneration. The approach to gain stability lobe diagram (SLD) through analytical or time-domain solutions is the most established method for predicting and avoiding regenerative chatter [1][2][3][4][5][6][7][8][9]. For example, the zeroth-order approximation (ZOA) method [1], the semi-discretization method (SDM) [2] and full-discretization method [3], etc.…”

Section: Introductionmentioning

confidence: 99%

Stability analysis of milling with variable pitch tools considering the variable cutting force coefficients with spindle speed

Jin¹,

Li²,

Han³

et al. 2016

Proceedings of the 2nd International Conference on Advances in Mechanical Engineering and Industrial Informatics (AMEII 2016)

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Abstract. The combination of increased strain rate and thermal softening of the workpiece at higher cutting speeds will cause the change of cutting force coefficients. In this paper, a vibration model for milling process, which can consider the variable cutting force coefficients (VCFC) with the spindle speed and the variable pitch angle was proposed after some experimental investigations which mainly pay attention to the connection between spindle speed and cutting force coefficients. Then, an updated semi-discretization method is used to predict the stability of such system. The method is also applied to examine the stability trend for different radial immersion ratios and speed regions. Results show that VCFC has great effect on the stability lobes, especially for higher-speed region and smaller radial immersion ratios, whether milling process with uniform or variable pitch angle.

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Analytical prediction of chatter stability for variable pitch and variable helix milling tools

Cited by 178 publications

References 30 publications

Operational stability prediction in milling based on impact tests

Operational stability prediction in milling based on impact tests

Effect of wavy tool path on the stability properties of milling by the implicit subspace iteration method

Stability analysis of milling with variable pitch tools considering the variable cutting force coefficients with spindle speed

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