Influence of Material Removal on the Dynamic Behavior of Thin-Walled Structures in Peripheral Milling

Thevenot, Vincent; Arnaud, Lionel; Dessein, Gilles; Cazenave-Larroche, Gilles

doi:10.1080/10910340600902082

Cited by 106 publications

(33 citation statements)

References 10 publications

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“…Then they obtained constant cutting coefficients averaging in the static chip thickness and iterating until completion of the stability diagram. Finally, Budak and Altintas proposed the discretization of the geometry of the tool to consider the stability of several nodes in cut [18]. This method was initially proposed to study the influence of the variation of the modal parameters along the tool axis but it can be applied to varying tool geometries [31].…”

Section: Stability Model Of the Milling Of Flexible Systems In The Tomentioning

confidence: 99%

“…The first is the material removal which reduces the mass and the stiffness of the part [16,17]. The second is related to the displacement of the tool over the modes of vibration of the part, e.g., when the tool is machining over a nodal point of a mode, that mode is negligible [18]. The third reason is the variation of the modal parameters in the cutting area [19][20][21][22].…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

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: Stability Model Of the Milling Of Flexible Systems In The Tomentioning

confidence: 99%

Section: Introductionmentioning

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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“…In order to stage this defect, Lapujoulade et al [11] studied the part per small zones. In these zones, the part was able to be modelled with constant dynamic properties and with rigid body motion [12]. The stability lobe change during machining that lead to a third dimension on the stability lobe [13,14].…”

Section: Introductionmentioning

confidence: 99%

Simulation of low rigidity part machining applied to thin-walled structures

Arnaud

Gonzalo

Seguy

et al. 2010

Int J Adv Manuf Technol

107

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OATAO is an open access repository that collects the work of Toulouse researchers and makes it freely available over the web where possible.Simulation of low rigidity part machining applied to thin-walled structuresAbstract The aim of this study is to evaluate the modelling of machining vibrations of thin-walled aluminium workpieces at high productivity rate. The use of numerical simulation is generally aimed at giving optimal cutting conditions for the precision and the surface finish needed. The proposed modelling includes all the ingredients needed for real productive machining of thin-walled parts. It has been tested with a specially designed machining test with high cutting engagement and taking into account all the phenomena involved in the dynamics of cutting. The system has been modelled using several simulation techniques. On the one hand, the milling process was modelled using a dynamic mechanistic model, with time domain simulation. On the other hand, the dynamic parameters of the system were obtained step by step by finite element analysis; thus the variation due to metal removal and the cutting edge position has been accurately taken into account. The results of the simulations were compared to those of the experiments; the discussion is based on the analysis of the cutting forces, the amplitude and the frequency of the vibrations evaluating the presence of chatter. The specific difficulties to perfect simulation of thin-walled workpiece chatter have been finely analysed.

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“…Budak [7] studied not only the static deflexion of the wall but also developed a frequency domain simulation. In the thin wall case, this modelling cannot be applied directly, because the characteristics of the part strongly vary during machining [8,9], in particular with the remove material. The stability lobes change during machining, what leads to the addition of the third dimension, corresponding to the tool position [10].…”

Section: The State Of the Artmentioning

confidence: 99%

Surface roughness variation of thin wall milling, related to modal interactions

Seguy

Dessein

Arnaud

2008

International Journal of Machine Tools and Manufacture

149

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High-speed milling operations of thin walls are often limited by the so-called regenerative effect that causes poor surface finish. The aim of this paper is to examine the link between chatter instability and surface roughness evolution for thin wall milling. Firstly, the linear stability lobes theory for the thin wall milling optimisation was used. Then, in order to consider the modal interactions, an explicit numerical model was developed. The resulting nonlinear system of delay differential equations is solved by numerical integration. The model takes into account the coupling mode, the modal shape, the fact that the tool may leave the cut and the ploughing effect. Dedicated experiments are carried out in order to confirm this modelling. This paper presents surface roughness and chatter frequency measurements. The stability lobes are validated by thin wall milling. Finally, the modal behaviour and the mode coupling give a new interpretation of the complex surface finish deterioration often observed during thin wall milling.

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Influence of Material Removal on the Dynamic Behavior of Thin-Walled Structures in Peripheral Milling

Cited by 106 publications

References 10 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

Simulation of low rigidity part machining applied to thin-walled structures

Surface roughness variation of thin wall milling, related to modal interactions

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