Chatter prevention for milling process by acoustic signal feedback

Tsai, Nan-Chyuan; Chen, Din Chang; Lee, Rong Mao

doi:10.1007/s00170-009-2245-y

Cited by 59 publications

(17 citation statements)

References 13 publications

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“…(11) are determined as: In this paper, it is assumed that a relatively short cutting tool is used in the milling machine. Consequently, similar to the majority of previous works (e.g., [1,3,[5][6][7][8][9][10][11][12][13]), a lumped single degree of freedom model (SDOF) can be used for the cutting tool (due to its high rigidity). In this model, one dominant lateral mode of vibration is considered in each x-y directions; so, dynamics of the process is described as:…”

Section: Dynamics Of the Peripheral Milling Process With Tool Wear Anmentioning

confidence: 94%

“…Tunable and optimal vibration absorbers and tuned viscoelastic dampers which have been used for chatter suppression in turning and milling processes are among the passive methods, respectively [2,3]. Also, spindle speed regulation and acoustic signal feedback have been investigated to avoid the chatter phenomenon [4,5]. Use of model reference adaptive control to achieve constant cutting forces as an active control method has been studied [4].…”

Section: Introductionmentioning

confidence: 98%

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Global Optimization and Design of Dynamic Absorbers for Chatter Suppression in Milling Process with Tool Wear and Process Damping

2014

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Peripheral milling is extensively used in manufacturing processes, especially in aerospace industries where end mills are used for milling of wing parts and engine components. The generation of complex shapes with high quality for various types of materials is the main advantage of milling in contrast to other machining processes. During the milling process, the occurrence of self-excited vibrations or chatter may cause reduction in material removal rate (MRR), damage to the tool and spindle bearing or may result in poor dimensional accuracy and surface finish of the work-piece. In this paper, milling process is modeled as two degrees of freedom (2DOF) system in which the tool wear and process damping effects are considered. To suppress regenerative chatter (or self-excited vibrations), optimum tunable vibration absorbers (in x-y directions) are designed. A sophisticated optimization algorithm is developed to determine the optimum values of the absorber parameters (their mass and stiffness). The effects of tool wear, process damping and absorbers are investigated on the frequency response of the system. Results are presented in the time and frequency domains. According to the results, both of the tool wear and process damping play as stabilizing factors of the dynamic system; under regenerative chatter and unstable machining conditions. However, tuned vibration absorbers are implemented to achieve the global stable conditions. The robustness and efficiency of deigned absorbers are investigated for the uncertain dynamic model. It is shown that after implementation of the absorbers, higher material removal rate (MRR) can be achieved while the stability of the nominal and uncertain processes is guaranteed.

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Section: Dynamics Of the Peripheral Milling Process With Tool Wear Anmentioning

confidence: 94%

Section: Introductionmentioning

confidence: 98%

Global Optimization and Design of Dynamic Absorbers for Chatter Suppression in Milling Process with Tool Wear and Process Damping

2014

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“…Numerous research outcomes on linear compressors have been reported [11][12][13][14]. Nevertheless, using AMBs to replace conventional bearings [15][16][17][18][19][20][21][22] for linear compressors has never been addressed.…”

Section: Introductionmentioning

confidence: 96%

Innovative linear compressor by magnetic drive and control

Tsai

Chiang

2011

Proceedings of the Institution of Mechanical Engineers, Part I:

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A mathematical model for the magnetically levitated linear compressor (MLLC), which consists of a magnetic linear actuator, a pair of active magnetic bearings (AMBs), and a drive rod, has been developed. To prevent any potential wear or collision by the drive rod against conventional bearings, and certainly to reduce noise, the AMB pair is employed to regulate the lateral position deviation of the drive rod. The integral sliding mode control (ISMC) is synthesized to account for displacement-dependent system parameters and input non-linearities for the MLLC system. In addition, the closed-loop stability, under the presence of the reaction force by gas in the chamber, is proven by the Lyapunov direct method. Finally, the efficacy of the ISMC is verified by intensive computer simulations to ensure its superior regulation capability for lateral position deviation on the drive rod, retention of constant stroke of the piston, and counterbalance against the reaction force by gas during the Otto cycle.

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“…Various effective strategies have been utilized to suppress chatter, such as vibration absorbers [26] and tuned viscoelastic dampers [27]. Tsai et al [28] investigated spindle speed regulation and acoustic signal feedback to prevent chatter. Abele et al [29] implemented piezoelectric active vibration control systems for chatter avoidance.…”

Section: Introductionmentioning

confidence: 99%

Three-dimensional stability prediction and chatter analysis in milling of thin-walled plate

Zhao

Wang

2016

Int J Adv Manuf Technol

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Stability lobe diagram can be used for selecting proper milling parameters to perform chatter-free operations and improve productivity during milling of thin-walled plates. This paper studies the machining stability in milling of thin-walled plates and develops a three-dimensional stability lobe diagram of the spindle speed, tool position, and axial depth of cut. The workpiece-holder system is modeled as a 2-degree-of-freedom system considering that the tool system is much more rigid than the thin-walled plate, and dynamic equations of motion described for the workpieceholder system are solved numerically in time domain to compute the dynamic displacements of the thin-walled plate. Statistical variances of the dynamic displacements are then employed as a chatter detection criterion to acquire the stability lobe diagram. The experimentally obtained stability limits correspond well with the predicted stability limits. In addition, influence of feed rate on stability limits is also investigated. By performing frequency analysis of the measured cutting forces to judge if chatter occurs, it is found that feed per tooth has little influence on the stability limits. However, feed per tooth impacts the machined surface quality. The results show that the surface quality drops by increasing feed per tooth.

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Chatter prevention for milling process by acoustic signal feedback

Cited by 59 publications

References 13 publications

Global Optimization and Design of Dynamic Absorbers for Chatter Suppression in Milling Process with Tool Wear and Process Damping

Global Optimization and Design of Dynamic Absorbers for Chatter Suppression in Milling Process with Tool Wear and Process Damping

Innovative linear compressor by magnetic drive and control

Three-dimensional stability prediction and chatter analysis in milling of thin-walled plate

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