Generalized design method of highly-varied-helix end mills for suppression of regenerative chatter in peripheral milling

Hayasaka, Takehiro; Ito, Atsushi; Shamoto, Eiji

doi:10.1016/j.precisioneng.2016.11.004

Cited by 33 publications

(9 citation statements)

References 13 publications

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“…8, the phase difference of Δɛ = π decreases the process stability because the nondiagonal terms of delay matrix that is amplified by SDM produce the large mode coupling effect. A simple method to eliminate mode coupling is to regulate the radial depth of cut [23]. For instance, the stability improvement with Δɛ = π were observed in the quarter immersion down cutting where α 0zz = 0.162, α 0zy = -0.377, α 0yz = 0.289, and α 0yy = -0.424.…”

Section: Asymptotic Borderlinementioning

confidence: 99%

Development of Automatic Chatter Suppression System in Parallel Milling by Real-Time Spindle Speed Control with Observer-Based Chatter Monitoring

Yamato

Nakanishi

Suzuki

et al. 2021

Int. J. Precis. Eng. Manuf.

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To maximize the potential for high material removal rates in simultaneous processes such as parallel milling, developing strategies for successful chatter suppression/avoidance is an important concern for manufacturers. In this study, the effectiveness of the spindle speed difference method (SDM) for chatter suppression is discussed in a parallel end-milling process where a flexible workpiece is machined by two tools rotating in opposite direction. The process model is developed, considering that the dynamic variation due to the regenerative effect occurs on a plane perpendicular to the tool axis direction. Through the process simulations and the experiments, this study provides informative discussion for comprehending the process behavior. Additionally, a real-time active chatter suppression system with adaptive SDM, where the spindle speed difference is sequentially optimized during the process according to the tracked chatter frequency, is developed by integrating a chatter monitoring system based on sensorless cutting force estimation with sliding discrete Fourier transform. The results show that the developed real-time adaptive system of spindle speed suppresses chatter vibrations more effectively than non-adaptive SDM system; hence, the integrated system can contribute self-optimizing machining systems oriented to Industry 4.0. Keywords Parallel milling • Chatter • Process control • Speed difference method • Disturbance observer Abbreviations a p Axial depth of cut a t Acceleration of table c f Feed per tooth dF t , dF r , dF a Minute cutting force in tool tangential, radial, and axial directions dF x , dF y , dF z Minute cutting force in Cartesian coordinate system F cut Cutting force F stat Non-process-related force including friction and gravity terms F x , F y , F z Cutting force in Cartesian coordinate system g(θ) Unit step function to judge tooth engagement G(iω) Frequency response function G LPF (s) Low-pass filter h Uncut chip thickness I a ref Motor current reference J r Total inertia of motor, coupling, and ball screw k c Chatter lobe number K t Torque coefficient K te , K re , K ae Edge force coefficient in tangential, radial, and axial directions K tc , K rc , K ac Cutting force coefficients in tangential, radial, and axial directions

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Section: Asymptotic Borderlinementioning

confidence: 99%

Development of Automatic Chatter Suppression System in Parallel Milling by Real-Time Spindle Speed Control with Observer-Based Chatter Monitoring

Yamato

Nakanishi

Suzuki

et al. 2021

Int. J. Precis. Eng. Manuf.

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show abstract

“…With the broad application of high speed milling technology, end mills are widely used in the rough, semi-fine, and fine finishing stages of a workpiece due to the advantages of flexible processing and small cutting resistance. 1–6 Peripheral milling is characterized by the axis of tool rotation parallel to the machined surface. The cutting edges are distributed on the cylindrical surface of the milling cutter to form a plane (or surface).…”

Section: Introductionmentioning

confidence: 99%

Modelling and simulation of surface topography machined by peripheral milling considering tool radial runout and axial drift

Chen

Wang

2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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Based on the Z-map model of a workpiece and the dynamic cutting forces model of peripheral milling in which the regenerative effect of tool radial runout and axial drift are considered, a model for the prediction of surface topography in peripheral milling operations is presented. According to the stability lobe diagram obtained by the zero-order analytical method, the relationship between spindle speed and surface topography, the tool radial runout, and the axial drift following the chatter are studied. The results show that a stable cutting status but a poor surface finish is obtained at the spindle speeds at which the dominant frequency of the milling system is integral multiples of the selected machining frequency, and a stable cutting status with a good surface finish can be obtained near and on the left side of the resonant spindle speeds determined by the predicted stability lobe diagram. The motion equations of any tooth end mill for peripheral milling are established, and these equations are based on the transformation matrix and the vector operation principle of motion-homogeneous coordinates. In addition, the simulation algorithm and the system of surface topography generated in peripheral milling are given based on the Z-map model. Cutting tests are carried out, and good agreement between the measured surface topographies and the topographies predicted by the model in this study is found in terms of their shape, magnitude, feed mark, profile height of cross-section, and surface roughness. The simulation results show that the milling surface roughness increases with the increase in feed per tooth, which further shows that this simulation system has high credibility. Thus, the simulation and experimental results can provide some practical instructions for the actual peripheral milling in determining the optimal machining conditions.

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“…Many works have been devoted to the issues of detection (Berczyński et al, 2001;Kuljanic et al, 2008;Liu et al, 2018;Yao et al, 2010;Jasiewicz and Powałka, 2018b), identification (Cao et al, 2013;Rusinek et al, 2015) and counteracting this phenomenon (Hayasaka et al, 2017;Munoa et al, 2016;Suzuki et al, 2016). Researchers mention the high importance of developing a reliable model, validated based on the results of experimental research, with particular emphasis on the representation of machine tool dynamics.…”

Section: Introductionmentioning

confidence: 99%

Application of the finite element method in the milling process stability diagnosis

Dunaj

Marchelek

Chodźko

2019

Journal of Theoretical and Applied Mechanics

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The article presents results of both experimental and FEM model-based investigations on chatter phenomena that occur in the end milling process. On the basis of chatter symptoms observed during machining, the mechanism of its occurrence has been identified. Then, a FEM model has been built to indicate machine tool elements responsible for loss of stability. Afterwards, experimental modal analysis has been conducted in order to validate the FEM model. Finally, on the basis of the validated model, the structural changes have been proposed and applied in the real object resulting in increased stability.

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Generalized design method of highly-varied-helix end mills for suppression of regenerative chatter in peripheral milling

Cited by 33 publications

References 13 publications

Development of Automatic Chatter Suppression System in Parallel Milling by Real-Time Spindle Speed Control with Observer-Based Chatter Monitoring

Development of Automatic Chatter Suppression System in Parallel Milling by Real-Time Spindle Speed Control with Observer-Based Chatter Monitoring

Modelling and simulation of surface topography machined by peripheral milling considering tool radial runout and axial drift

Application of the finite element method in the milling process stability diagnosis

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