Chatter suppression techniques in metal cutting

Muñoa, Jokin; Beudaert, Xavier; Dombóvári, Zoltán; Altintaş, Yusuf; Budak, Erhan; Brecher, Christian; Stépàn, Gábor

doi:10.1016/j.cirp.2016.06.004

Cited by 558 publications

(232 citation statements)

References 241 publications

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“…Sun et al 3 studied the formation of chips during dry turning of Ti6Al4V alloy and found that the cutting forces and chip formation in machining of titanium alloys were related to cutting speed, feed rate, and cutting depth. Munoa et al 4 pointed out that the appearance of chatter on machine tools was disastrous since it prevented from obtaining the required surface finishes and decreased the life of tools and mechanical components. Cao et al 5 pointed out that the chatter stability of machine tool was dependent on the dynamic behavior of spindle systems and presented an alternative method to predict the chatter stability lobes of high-speed milling with consideration of speedvarying spindle dynamics.…”

Section: Introductionmentioning

confidence: 99%

A prediction model of the surface topography due to the unbalance of the spindle system in ultra-precision fly-cutting machining

Chen

Cui

Pan

et al. 2018

Advances in Mechanical Engineering

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In ultra-precision fly-cutting machining, the aerostatic spindle is the key component, which has significant influence on the machined surface quality. The unbalanced spindle directly affects the machining accuracy. In this article, a prediction model of machining surface topography is proposed which involves the effect of the gas film performance of spindle in microscale. With the Weierstrass function, unstable transient response of the aerostatic spindle system is derived by the motion model of the spindle, which response signal represents the surface profile in the ultra-precision machining. Meanwhile, the experiment is performed with different rotation speed of the spindle. And the effect of the unbalanced aerostatic spindle on the surface generation is discussed in time and frequency domain. The conclusion shows that the similar cyclical surface ripple of the workpiece is independent of the spindle speed, and the rotation speed of the spindle and unbalanced spindle directly affects the machining surface topography. This study is quite meaningful for deeply understanding the influence rule of spindle unbalanced error from the viewpoint of machined surface and vibration frequency.

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Section: Introductionmentioning

confidence: 99%

A prediction model of the surface topography due to the unbalance of the spindle system in ultra-precision fly-cutting machining

Chen

Cui

Pan

et al. 2018

Advances in Mechanical Engineering

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“…Other techniques utilize directly the measured signals in time domain based on considerations of the periodic behavior of the system [22,27,28]. A more detailed study on chatter suppression methods is given by [29], and for a review on chatter detection, see [30] and all the reference therein.…”

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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“…In more advanced applications, actively damped tool holders or workpiece clamping systems with sensor systems and actuators can be found. Also, semi-active damping systems that can be adjusted during the machining operations has been demonstrated, for example by the use of magnetorheological fluid [2].…”

Section: Introductionmentioning

confidence: 99%

“…At longer overhang, a passive vibration damper, also denoted as Tuned Mass Damper (TMD), is commonly used to increase the dynamic stiffness of the boring bars [2]. The TMD is attached inside the boring bar close to the free end.…”

Section: Introductionmentioning

confidence: 99%

Development and Optimization of Vibration-Damped Tool Holders for High Length-to-Diameter Boring Operations

Sørby¹

2016

High Speed Machining

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When the length-to-diameter ratio of a boring bar becomes too high, the vibration problem becomes excessive. This paper discusses the design and optimization of tuned mass dampers (TMDs) for vibration-damped boring bars. A typical TMD for a boring bar consists of a high-density mass, rubber elements, and viscous damping fluid. The TMD is mounted as close to the free end of the boring bar as possible for maximizing the damping effect. The different tuning strategies are related to the different types of vibrations that are observed in machining operations. It is shown that the classical tuning with minimized magnitude of the frequency response function will give the shortest settling time for free vibrations, while tuning for maximized negative real part of the frequency response function will give the highest resistance to regenerative chatter. For suppressing regenerative chatters, the internal damping in the material in the boring bar body is of minor importance for boring bars with TMDs, but of high importance for conventional undamped boring bars. The paper presents design solutions for TMDs in boring bars.

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Chatter suppression techniques in metal cutting

Cited by 558 publications

References 241 publications

A prediction model of the surface topography due to the unbalance of the spindle system in ultra-precision fly-cutting machining

A prediction model of the surface topography due to the unbalance of the spindle system in ultra-precision fly-cutting machining

Operational stability prediction in milling based on impact tests

Development and Optimization of Vibration-Damped Tool Holders for High Length-to-Diameter Boring Operations

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