Chatter stability prediction of milling considering nonlinearities

Yang, Yiqing; Wu, Donghui; Liu, Qiang

doi:10.1177/0954405420971075

Cited by 8 publications

(5 citation statements)

References 22 publications

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“…Combining equations ( 1)-( 3), the air damping coefficient c a of the damper can be obtained as equation (4).…”

Section: Air Dampingmentioning

confidence: 99%

“…Sims and Turner 3 developed a time domain model of process damping, and explored the relationship between cutting conditions and the amplitude of chatter vibrations. Yang et al 4 proposed a numerical solution based on perturbation and iteration methods to solve the cutting force, vibration, and chatter stability of thin-walled part milling. Liu et al 5 proposed a tool inclination method based on the adoption of the cutting force component in the lowest stiffness direction of the thin-walled part to guarantee the machined surface finish.…”

Section: Introductionmentioning

confidence: 99%

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Design of a composite viscous damper and application on cylindrical thin-walled part milling

Chen

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Chatter vibration is apt to occur when machining thin-walled parts with insufficient rigidity. The harmful excitation of periodical cutting forces can be mitigated by enhancing the dynamic stiffness or increasing the damping of the part. A composite viscous damper including air damping and eddy current damping is designed, which can be attached on the thin-walled part by the vacuum. Based on the formulations of air damping and eddy current damping, the optimal equivalent viscous damping is derived for achieving the maximum critical depth of cut. Furthermore, the geometries of the damper are determined for damping a specific thin-walled part after investigating its relationship with viscous damping. The modal test indicates that the damper can suppress multiple modes of the cylindrical thin-walled part, and the amplitude of the first mode of the frequency response function (FRF) is reduced by 57%. The composite viscous damper is applied to suppress the chatter and resonant vibration of the thin-walled part during machining. Milling tests demonstrate that the machining vibration is reduced by 55% and 76% after employing single damper and four dampers, respectively.

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“…Combining equations ( 1)-( 3), the air damping coefficient c a of the damper can be obtained as equation (4).…”

Section: Air Dampingmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Design of a composite viscous damper and application on cylindrical thin-walled part milling

Chen

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…[9][10][11][12] The mechanism destroying micromilling machinability has not been revealed fully. 13,14 In the micro-milling of thin-walled parts, regenerative chatter is one of the main challenges due to the low 1 School of Mechanical and Electrical Engineering, Harbin Institute of Technology, Harbin, China stiffness and high spindle speed of the machining system, which makes it the most direct and unfavorable factor causing the decrease in machinability. 15 Micromilling instability can lead to poor surface integrity, premature tool failure, low machining efficiency, etc.…”

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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“…Moreover, monitoring technology can meet the above-mentioned requirements. Among all the monitored variables, the cutting force is the most important one, whose measurement can be used as predicting tool wear, 1 understanding the principle of chip formation, 2 tool geometry design, 3 monitoring tool condition, 4 predicting chatter, 5 and optimizing the machining parameters. 6 Therefore, it is essential to monitor the cutting force timely and accurately.…”

Section: Introductionmentioning

confidence: 99%

Development and testing of a wireless multi-axis toolholder dynamometer for milling and drilling process

Zhang

Gao

Lü

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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The cutting force provides important information such as tool condition, chips information, and machining parameters selection. Thus, many researchers have proposed some methods for cutting force monitoring. However, most of them are only applied in the laboratory due to lower flexibility and complex installation. In this paper, a split multi-axis toolholder dynamometer is proposed and developed, which can equip different types of machining spindle and fit for multi-size tool. It consists of six capacitive sensors that can sense four deformations in vertical direction and two deformations in circumferential direction. Meanwhile, the distance between two plates in the vertical and circumferential capacitive sensors was adjusted separately. An acquisition and wireless transmission unit was designed to detect the capacitive variation and then transfer data to upper computer. Finally, a standard tool holder and a force sensing unit, a bottom socket, an acquisition and wireless transmission unit, a lithium battery, a cover were installed and debugged as a whole system. To validate its static and dynamic characteristics, various tests are conducted. The result demonstrates that the toolholder dynamometer can accurately and reliably monitor four-axis cutting force in the milling and drilling operations.

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Chatter stability prediction of milling considering nonlinearities

Cited by 8 publications

References 22 publications

Design of a composite viscous damper and application on cylindrical thin-walled part milling

Design of a composite viscous damper and application on cylindrical thin-walled part milling

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

Development and testing of a wireless multi-axis toolholder dynamometer for milling and drilling process

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