Limit cycles, bifurcations, and accuracy of the milling process

Mann, Brian P.; Bayly, Philip V.; Davies, M.A.; Halley, Jeremiah E.

doi:10.1016/j.jsv.2003.08.040

Cited by 110 publications

(73 citation statements)

References 18 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The stability of interrupted cutting has been studied by Merdol and Altintas [18] (who used a Fourier series expansion of the periodic cutting forces), Insperger et al [19,20] ( who used a semi-discretisation approach) and Mann et al [21] who used a temporal finite element method). It should be noted that to the authors' knowledge none of this previous work has demonstrated the existence of cyclic fold bifurcations, and it has focussed on regular pitch and regular helix tools.…”

Section: Introductionmentioning

confidence: 99%

Analytical prediction of chatter stability for variable pitch and variable helix milling tools

Sims

Mann

Huyanan

2008

Journal of Sound and Vibration

178

120

View full text Add to dashboard Cite

Regenerative chatter is a self-excited vibration that can occur during milling and other machining processes. It leads to a poor surface finish, premature tool wear, and potential damage to the machine or tool. Variable pitch and variable helix milling tools have been previously proposed to avoid the onset of regenerative chatter. Although variable pitch tools have been considered in some detail in previous research, this has generally focussed on behaviour at high radial immersions. In contrast there has been very little work focussed on predicting the stability of variable helix tools. In the present study, three solution processes are proposed for predicting the stability of variable pitch or helix milling tools.The first is a semi-discretisation formulation that performs spatial and temporal discretisation of the tool. Unlike previously published methods this can predict the stability of variable pitch or variable helix tools, at low or high radial immersions.The second is a time-averaged semi-discretisation formulation that assumes time-averaged cutting force coefficients. Unlike previous work, this can predict stability of variable helix tools at high radial immersion.The third is a temporal-finite element formulation that can predict the stability of variable pitch tools with a constant uniform helix angle, at low radial immersion.

show abstract

Section: Introductionmentioning

confidence: 99%

Analytical prediction of chatter stability for variable pitch and variable helix milling tools

Sims

Mann

Huyanan

2008

Journal of Sound and Vibration

178

120

View full text Add to dashboard Cite

show abstract

“…Looking for minimum in the average mutual information to determine the i we obtained 7,8,6,4, and 7, respectively, for increasing spindle speed (2,000, 3,500, 5,000, 6,500 to 8,000 rpm) [11]. In further analysis, we estimated the embedding delay for the system to i = 7.…”

Section: Embedding and Recurrence Plots Analysismentioning

confidence: 99%

“…Over the past years, its fast development gave way to a reliable high-speed cutting procedure. Consequently, elimina-tion and stabilization of the associated chatter oscillations have become a high interest in science and technology [1][2][3][4][5][6][7]. The plausible adaptive control concept, based on relatively short time series, is studied to gain deeper understanding.…”

Section: Introduction and Experimental Datamentioning

confidence: 99%

Dynamical changes during composite milling: recurrence and multiscale entropy analysis

Litak

Syta

Rusinek

2011

Int J Adv Manuf Technol

View full text Add to dashboard Cite

Fluctuations describing chatter in the milling process of a composite material were analyzed using statistical, recurrence, and multiscaled entropy analyses. Through changing the rotational speed, we observed the appearance of chatter vibrations and signatures of intermittency. The corresponding characteristic change of recurrences could be used to invent a new efficient control procedure of milling. The workpiece was prepared from nonuniform material based on epoxy-polymer matrix composite reinforced by carbon fibers.

show abstract

“…Of particular relevance is the work of Mann et al [4], who used techniques from non-linear dynamics (onceper-period sampling, and Poincaré sections) to analyses numerical and experimental data. The focus of their work, however, was the chatter vibrations that occur at very low radial immersions, rather than the behaviour at low spindle speeds.…”

Section: Literature Reviewmentioning

confidence: 99%

The influence of feed rate on process damping in milling: modelling and experiments

Sims

Turner

2011

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

eprints@whiterose.ac.uk https://eprints.whiterose.ac.uk/ Reuse Unless indicated otherwise, fulltext items are protected by copyright with all rights reserved. The copyright exception in section 29 of the Copyright, Designs and Patents Act 1988 allows the making of a single copy solely for the purpose of non-commercial research or private study within the limits of fair dealing. The publisher or other rights-holder may allow further reproduction and re-use of this version -refer to the White Rose Research Online record for this item. Where records identify the publisher as the copyright holder, users can verify any specific terms of use on the publisher's website. TakedownIf you consider content in White Rose Research Online to be in breach of UK law, please notify us by emailing eprints@whiterose.ac.uk including the URL of the record and the reason for the withdrawal request. DOI: 10.1243/09544054JEM2141Abstract: The performance of milling operations is limited by the onset of unstable self-excited vibrations known as regenerative chatter. Over the past few decades there has been a great deal of research to help predict and explain regenerative chatter. Consequently, high-speed milling operations are now frequently employed, with judicious choice of spindle speeds and depths of cut so as to avoid chatter whilst maintaining high productivity. However, many materials that are increasingly used in aerospace components are difficult to machine at high spindle speeds because of their thermal properties. Examples include titanium and nickel alloys. For these materials, low-speed machining must be employed, and in this regime the role of regenerative chatter is less clearly understood due to the phenomenon of process damping. In the present study, a time domain model of process damping is developed. This model is used to explore the relationship between cutting conditions and the amplitude of chatter vibrations. A qualitative agreement is found between experimental behaviour and the numerical model. In particular, the model predicts a strong relationship between the workpiece feed rate (expressed as a feed per tooth), and the acceptable chatter stability defined by the process damping wavelength. Further work is needed to properly calibrate some of the model parameters.

show abstract

Limit cycles, bifurcations, and accuracy of the milling process

Cited by 110 publications

References 18 publications

Analytical prediction of chatter stability for variable pitch and variable helix milling tools

Analytical prediction of chatter stability for variable pitch and variable helix milling tools

Dynamical changes during composite milling: recurrence and multiscale entropy analysis

The influence of feed rate on process damping in milling: modelling and experiments

Contact Info

Product

Resources

About