Regenerative delay, parametric forcing and machine tool chatter: A review

Insperger, Tamás; Lehotzky, Dávid; Stépàn, Gábor

doi:10.1016/j.ifacol.2015.09.398

Cited by 31 publications

(8 citation statements)

References 48 publications

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“…In order to achieve high-efficiency chatter-free EUVAM, the dynamics of the vibration-assisted milling process should be modeled accurately. Although the stability of conventional milling operations has been studied extensively in the literatures [5,6], the stability of milling under ultrasonic vibrations has not been investigated sufficiently. Xiao et al [7] numerically and experimentally studied the chatter stability of a 1-DOF vibration-assisted turning process and reported achieving a larger depth of cut, but they did not predict stability lobes of the process.…”

Section: Introductionmentioning

confidence: 99%

Z-map based cutting force prediction for elliptical ultrasonic vibration-assisted milling process

Xiao

Han

et al. 2022

Int J Adv Manuf Technol

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Elliptical ultrasonic vibration-assisted milling (EUVAM) adds high-frequency vibration to conventional milling (CM) to realize high-frequency intermittent milling. It has broad application prospects in the processing of difficultto-cut materials such as titanium alloys, superalloys and hard and brittle materials. To reveal the mechanism of the highly intermittent cutting nature in EUVAM, according to the motion relationship between cutting edge and workpiece and the Z-map model of the workpiece, a method and its algorithm for calculating undeformed cutting thickness and thus the cutting force in EUVAM are proposed. The simulation results show that EUVAM can improve the actual cutting speed when compared with CM, and the proportion of idle cutting time will directly determine the intermittent degree of the milling process. The experiment of EUVAM is performed to verify the correctness of the proposed cutting force model, and the impact of spindle speed on the cutting force in EUVAM is also analyzed.

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Section: Introductionmentioning

confidence: 99%

Z-map based cutting force prediction for elliptical ultrasonic vibration-assisted milling process

Xiao

Han

et al. 2022

Int J Adv Manuf Technol

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“…In 1946, British scholar Arnold [22] used experiments to prove for the first time that the cutting force within a certain range of cutting speed decreases with the increase of cutting speed. Regarding regenerative chatter, in recent years, many scholars have carried out modeling, simulation, and experimental studies on various cutting chatter problems, as well as chatter monitoring and control on the basis of considering different processing types and influencing factors of chatter [23][24][25][26][27][28][29]. Zhang and Liu [30] established a multi-degree-of-freedom chatter model of the tool-workpiece system in modal coordinates to decouple the delay differential equation.…”

Section: Introductionmentioning

confidence: 99%

Cutting Force and Nonlinear Chatter Stability of Ball-end Milling Cutter

Zhang

et al. 2021

Preprint

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Ball-end milling cutters are one of the most widely used cutters in the automotive, aerospace, die and machine parts industries. In addition, milling chatter will reduce the surface quality and production efficiency, resulting in noise. It is particularly important to model the cutting force and analyze the flutter stability of ball-end milling cutters. In this paper, a simplified milling force model of ball-end milling cutter with three degrees of freedom was established based on Merchant bevel cutting theory. The model simplified the milling force coefficient. The expressions of instantaneous milling area considering the vibration displacements in X, Y and Z directions were derived. The nonlinear dynamic cutting force model of ball-end milling cutter with three degrees of freedom was established. The nonlinear chatter vibration mechanical model of ball-end milling cutter with three degrees of freedom was established by introducing the time delay term, the stability analysis is carried out by time domain simulation. The proposed models were experimentally verified.

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“…There are different methods of calculating the SLD, and they can be categorized into time domain and frequency domain methods [10]. Efficient time domain methods include the spectral element method [11] and the Chebychev collocation method [12].…”

Section: Introductionmentioning

confidence: 99%

Chatter prediction for uncertain parameters

et al. 2018

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The occurrence of chatter in milling processes was investigated in this study. The prediction of the stability lobes of metal cutting processes requires a model of the cutting force and a model of the dynamic machine tool behavior. Parameter uncertainties in the models may lead to significant differences between the predicted and measured stability behavior. One approach towards robust stability consists of running a large number of simulations with a random sample of uncertain parameters and determining the confidence levels for the chatter vibrations, which is a time-consuming task. In this paper, an efficient implementation of the multi frequency solution and the construction of an approximate solution is presented. The approximate solution requires the explicit calculation of the multi frequency solution only at a few parameter points, and the approximation error can be kept small. This study found that the calculation of the robust stability lobe diagram, which is based on the approximate solution, is significantly more efficient than an explicit calculation at all random parameter points. The numerically determined robust stability diagrams were in good agreement with the experimentally determined stability lobes.

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Regenerative delay, parametric forcing and machine tool chatter: A review

Cited by 31 publications

References 48 publications

Z-map based cutting force prediction for elliptical ultrasonic vibration-assisted milling process

Z-map based cutting force prediction for elliptical ultrasonic vibration-assisted milling process

Cutting Force and Nonlinear Chatter Stability of Ball-end Milling Cutter

Chatter prediction for uncertain parameters

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