Milling stability prediction and adaptive chatter suppression considering helix angle and bending

Wang, Chenxi; Zhang, Xingwu; Xiang, Jiawei

doi:10.1007/s00170-017-1389-4

Cited by 20 publications

(5 citation statements)

References 26 publications

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“…As shown in [4], the cutting part of a milling tool is divided into N a slices along the axial direction; therefore, the thickness of each slice is ∆a p = a p /N a and the height of the ith slice is z = i × ∆a p . Considering the helix and feed effects, the governing equation can be given by [13] M ..…”

Section: Helix Angle and Surface Location Errormentioning

confidence: 99%

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Difference Discretization Method for Milling Stability Prediction

Wang

2023

Metals

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This paper proposes a difference discretization method (DDM) under a difference frame for the prediction of milling stability. In this method, the dynamic milling process is described by a delay differential equation (DDE) with two degrees of freedom rather than the traditional state-space form with a single discrete time delay. After discretization, only the velocity and acceleration in the DDE are approximated by the first- and second-order central difference for each smaller time interval, while the other items are kept unchanged. Then, the criterion for the optimal discretization interval number is put forward and derived based on the largest effective time interval (also called the critical time interval). The use of the critical time interval cannot only obtain sufficient accuracy, but also promotes as much efficiency as possible. Subsequently, a new DDM (NDDM) with varied discretization interval numbers as the milling rotating speeds is developed. Finally, the effectiveness of the proposed algorithm is demonstrated by using a benchmark example for a two-degrees-of- freedom milling model compared to the full discretization method (FDM) and the Hermite-interpolation full discretization method (HFDM). The results show that the proposed method has satisfactory stability charts and is able to increase the efficiency by 100% or more.

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Section: Helix Angle and Surface Location Errormentioning

confidence: 99%

“…To avoid chatter, the milling parameters, such as spindle speed and axial and radial milling depth, should be selected carefully [3,4]. The selection of these parameters should be based on the characteristics of the workpiece, the cutting tool, and the machine tool being used.…”

Section: Introductionmentioning

confidence: 99%

Difference Discretization Method for Milling Stability Prediction

Wang

2023

Metals

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“…In [11] vibration damping by changing the cutting mode is proposed. In works [12,13,14] methods of optimization of elements of the cutting mode based on the construction of SLD -stability lobe diagram are considered. They help you select the right speed and depth of cut for high productivity without vibration.…”

Section: Mathematical Modelmentioning

confidence: 99%

Effect of Elements of the Cutting Conditions on the Amplitude of Vibration during End Milling

Topolov

Boldyrev

2022

KEM

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The choice of cutting mode elements in end milling has a significant effect on machining performance. However, an increase in these parameters leads to an increase in cutting force and vibration amplitude. Therefore, the designation of the elements of the cutting mode must be carried out taking into account the dynamic phenomena accompanying milling. The article shows the influence of the depth of cut on the amplitudes of forced vibrations. The choice of the optimal values of the cutting mode during end milling is proposed to ensure the minimum vibration amplitude.

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“…Compared with that without considering the helix angle effect, the stability limit curve with the helix angle effect was more accurate. Wang et al 32 used a new calculation method of milling force considering helix angle and bending, and improved the calculation method of instantaneous cutting area. It was found that tool bending and helix were crucial in stabilizing lobes.…”

Section: Introductionmentioning

confidence: 99%

Chatter stability analysis of variable speed milling with helix angled cutters

Xiong

Yuan

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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The number of factors considered in the establishing of chatter model for regenerative chatter would directly affect the accuracy of numerical analysis. In this paper, considering the helix angle of cutter, the establishment method of three degrees of freedom complex model is investigated synthetically. An improved semi-discretization method is adopted for the prediction of milling stability of variable speed milling with helix angle. The influences of milling cutter helix angle, radial immersion rate and variable speed modulation coefficient on chatter suppression in milling process are studied. The results show that the selection of milling cutters with different helix angles has a certain influence on the overall chatter stability, especially the effect cannot be ignored under local special machining conditions. Excessive radial immersion rate will increase the probability of chatter. Compared with constant speed milling, the chatter can be suppressed obviously by variable speed milling, and the selection of variable speed modulation coefficient will directly affect the suppression effect of chatter.

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Milling stability prediction and adaptive chatter suppression considering helix angle and bending

Cited by 20 publications

References 26 publications

Difference Discretization Method for Milling Stability Prediction

Difference Discretization Method for Milling Stability Prediction

Effect of Elements of the Cutting Conditions on the Amplitude of Vibration during End Milling

Chatter stability analysis of variable speed milling with helix angled cutters

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