2019
DOI: 10.1098/rsta.2018.0125
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Experimental observations on unsafe zones in milling processes

Abstract: The unsafe zone in machining is a region of the parameter space where steady-state cutting operations may switch to regenerative chatter for certain perturbations, and vice versa. In the case of milling processes, this phenomenon is related to the existence of an unstable quasi-periodic oscillation, the in-sets of which limit the basin of attraction of the stable periodic motion that corresponds to the chatter-free cutting process. The mathematical model is a system of time-periodic nonlinear delay dif… Show more

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Cited by 22 publications
(19 citation statements)
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“…This resonance caused by the stochastic excitation from the cutting force can be a potential explanation to the measurement difficulties of theoretically predicted stability charts [42,43]. Furthermore, these stationary vibrations can cause the transition to chatter in the multistable zones near the stability borders [6,44].…”
Section: Summary and Discussionmentioning
confidence: 99%
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“…This resonance caused by the stochastic excitation from the cutting force can be a potential explanation to the measurement difficulties of theoretically predicted stability charts [42,43]. Furthermore, these stationary vibrations can cause the transition to chatter in the multistable zones near the stability borders [6,44].…”
Section: Summary and Discussionmentioning
confidence: 99%
“…There are two main types of machine tool vibrations: chatter, which is a selfinduced oscillation caused by the surface regeneration effect [1]; and forced vibration, where the deviation in the cutting force is caused by the fast changes of the chip thickness, which can cause resonant vibrations in milling and interrupted turning processes. During the theoretical investigation of these vibrations, a widely used approach is to describe the vibrations with deterministic delayed differential equations which can be utilized for linear stability analysis of, e.g., milling operations [2][3][4][5] as well as nonlinear analysis of milling operations [6,7]. In these equations, the parameters (including the cutting force coefficients) are usually considered deterministic constants.…”
Section: Introductionmentioning
confidence: 99%
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“…With the final contribution by Dombovari et al [18], we close the loop and come back to time-delay dynamics in engineering, namely the impact of delays in metal cutting. In particular, undesired self-excited machine tool vibrations in milling can be explained by the regenerative effect, which is a closed-loop between tool vibrations at the present cut generated by a wavy surface left by the previous cut.…”
Section: Content Of the Issuementioning
confidence: 94%
“…Therefore, the interplay between the delay and the periodicity leads to more complicated behavior. Further, the transition from chatter-free to chatter in milling is not so simple, and it can occur for certain perturbations due to the existence of unsafe zones characterized by unstable quasi-periodic oscillation which limit the basin of attraction of the chatter-free stable periodic motion [20]. Chatter can even manifest as chaotic motion in some cases, further complicating its identification [21].…”
Section: Introductionmentioning
confidence: 99%