Chatter stability of milling in frequency and discrete time domain

Altintaş, Yusuf; Stépàn, Gábor; Merdol, Doruk; Dombóvári, Zoltán

doi:10.1016/j.cirpj.2008.06.003

Cited by 270 publications

(125 citation statements)

References 17 publications

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“…The stability algorithm can introduce an error in the solution, particularly if the single-frequency solution is used in interrupted milling. However, comparisons between analytical stability models and time domain models have demonstrated the poor influence of some of those hypotheses on the accuracy of the stability diagram in the lower order lobes area [43]. Hence, authors assume that the main source of error in the modelling in the present work comes from the averaging performed for the bull-nose end mill.…”

Section: Discussionmentioning

confidence: 99%

Chatter avoidance in the milling of thin floors with bull-nose end mills: Model and stability diagrams

Campa

Lacalle

Celaya

2011

International Journal of Machine Tools and Manufacture

122

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The milling of thin parts is a high added value operation where the machinist has to face the chatter problem. The study of the stability of these operations is a complex task due to the changing modal parameters as the part losses mass during the machining and the complex shape of the tools that are used. The present work proposes a methodology for chatter avoidance in the milling of flexible thin floors with a bull-nose end mill. First, a stability model for the milling of compliant systems in the tool axis direction with bullnose end mills is presented. The contribution is the averaging method used to be able to use a linear model to predict the stability of the operation. Then, the procedure for the calculation of stability diagrams for the milling of thin floors is presented. The method is based on the estimation of the modal parameters of the part and the corresponding stability lobes during the machining. As in thin floor milling the depth of cut is already defined by the floor thickness previous to milling, it is proposed the use of stability diagrams that relate the tool position along the tool-path with the spindle speed. Hence, the sequence of spindle speeds that the tool must have during the milling can be selected. Finally, this methodology has been validated by means of experimental tests.

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Section: Discussionmentioning

confidence: 99%

Chatter avoidance in the milling of thin floors with bull-nose end mills: Model and stability diagrams

Campa

Lacalle

Celaya

2011

International Journal of Machine Tools and Manufacture

122

View full text Add to dashboard Cite

show abstract

“…They are applied before cutting but need experimental information about machine/workpiece dynamics and cutting parameters. For instance, Cutpro ® developed by Prof. Y. Altintas is a well-known simulation software for chip removal processes that solves the process stability equation in the frequency domain [18]. Recently, this laboratory released new more complex software, MACHpro ® , to integrate the compliance of a given system into a CAM module aimed at tool path optimization (both trajectory and cutting parameters) from a dynamic point of view.…”

Section: Models In Machining Processesmentioning

confidence: 99%

A Reliable Turning Process by the Early Use of a Deep Simulation Model at Several Manufacturing Stages

et al. 2017

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Abstract:The future of machine tools will be dominated by highly flexible and interconnected systems, in order to achieve the required productivity, accuracy, and reliability. Nowadays, distortion and vibration problems are easily solved in labs for the most common machining operations by using models based on the equations describing the physical laws of the machining processes; however, additional efforts are needed to overcome the gap between scientific research and real manufacturing problems. In fact, there is an increasing interest in developing simulation packages based on "deep-knowledge and models" that aid machine designers, production engineers, or machinists to get the most out of the machine-tools. This article proposes a methodology to reduce problems in machining by means of a simulation utility, which uses the main variables of the system and process as input data, and generates results that help in the proper decision-making and machining plan. Direct benefits can be found in (a) the fixture/clamping optimal design; (b) the machine tool configuration; (c) the definition of chatter-free optimum cutting conditions and (d) the right programming of cutting toolpaths at the Computer Aided Manufacturing (CAM) stage. The information and knowledge-based approach showed successful results in several local manufacturing companies and are explained in the paper.

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“…They are applied before cutting but need experimental information from the system dynamics and cutting parameters. Cutpro® developed by Prof. Y. Altintas, is a well-known simulation software for chip removal processes that solves the process stability equation in the frequency domain [18]. Recently, this laboratory has released new more complex software, MACHpro®, to integrate the compliance of a given system into a CAM module aiming for tool path optimization (both trajectory and cutting parameters) from a dynamic point of view.…”

Section: Models In Machining Processesmentioning

confidence: 99%

A Reliable Turning Process by the Early Use of a Deep Simulation Model at Several Manufacturing Stages

Urbikaín¹,

Lacalle²,

Alonso³

et al. 2016

Preprint

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Abstract:The next future using machine tools will be dominated by highly flexible and interconnected systems, in order to achieve the required productivity, accuracy and reliability. Nowadays, distortion and vibration problems are easily solved for the most common cases by sing models based on equations describing the physical laws dominating the machining process; however additional efforts are needed to overcome the gap between scientific research and the real manufacturing problems. In fact, there is an increasing interest in developing simulation packages based on "deep knowledge and models" that aid the machine designer, the production engineer, or machinists to get the best of their machines. This article proposes a systematic methodology to reduce problems in machining by means of a simulation utility, which recognizes, collects and uses the main variables of the system/process as input data, and generates objective results that help in the proper decision-making. Direct benefits by such an application are found in a) the fixture/clamping optimal design, b) the machine tool configuration, c) the definition of chatter free optimum cutting conditions and the right programming of cutting tool path at the Computer Aided Manufacturing (CAM) stage. The information and knowledge-based approach showed successful results in several local manufacturing companies.

show abstract

Chatter stability of milling in frequency and discrete time domain

Cited by 270 publications

References 17 publications

Chatter avoidance in the milling of thin floors with bull-nose end mills: Model and stability diagrams

Chatter avoidance in the milling of thin floors with bull-nose end mills: Model and stability diagrams

A Reliable Turning Process by the Early Use of a Deep Simulation Model at Several Manufacturing Stages

A Reliable Turning Process by the Early Use of a Deep Simulation Model at Several Manufacturing Stages

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