The Effect of Flexible-Tool Rotation on Regenerative Instability in Machining

Li, Chen-Jung; Ulsoy, A. Galip; Endres, William J.

doi:10.1115/1.1536657

Cited by 27 publications

(12 citation statements)

References 19 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…It must be noted that design of Smart Tool boring bar and cutting conditions used to present this result were selected to meet non-chatter conditions. Readers interested in chatter analysis of Smart Tool are recommended to refer Li et al (1998) and Li (1999).…”

Section: Resultsmentioning

confidence: 99%

Integrated Structural/Control Design of Micro-Positioner for Boring Bar Tool Insert

O’Neal

Min

Pasek³

et al. 2001

Journal of Intelligent Material Systems and Structures

View full text Add to dashboard Cite

This paper presents a method to improve the performance of an electro-mechanical system by employing an integrated structural/control design methodology. In their previous work, the authors have introduced an intelligent boring bar, utilizing a micropositioner (composed of a piezoelectric actuator and photosensitive detectors) to actively control a cutting insert. The purpose of the micro-positioner was to improve precision of boring process by isolating the boring tool from tool vibrations and compensating tool position for geometric errors. The controller for the micro-positioner was designed only after the mechanical design was finalized. As a result, the controller performance was acceptable, but overall performance of the system was limited by its mechanical structure. This paper introduces a new approach of concurrent design of the mechanical structure and the controller to enhance the performance of the micro-positioner. With the proposed method, both mechanical and control design variables are determined simultaneously in a single optimization problem. The objective and constraint equations quantify system performance, stability, actuator saturation, and life expectancy as explicit functions of the design variables. The proposed integrated methodology both simplifies the design process of the prototype boring tool and enhances its performance over the previous design, as shown by simulation results.

show abstract

Section: Resultsmentioning

confidence: 99%

Integrated Structural/Control Design of Micro-Positioner for Boring Bar Tool Insert

O’Neal

Min

Pasek³

et al. 2001

Journal of Intelligent Material Systems and Structures

View full text Add to dashboard Cite

show abstract

“…But in machining processes, self-excited types of vibrations are the most harmful. The existence of self-excited vibration has been proved by several researchers in the past (Chandiramani et al, 2006;Latifi et al, 2017;Li et al, 2003;Shrivastava et al, 2018b). Wavy profile develops because of the inhomogeneous nature of the work material.…”

Section: CImentioning

confidence: 97%

Ensembled local mean decomposition and genetic algorithm approach to investigate tool chatter features at higher metal removal rate

Gupta

Singh

2020

Journal of Vibration and Control

View full text Add to dashboard Cite

Improper selection of cutting parameters leads to regenerative chatter and loss in productivity. In the present work, a methodology has been proposed to select a proper combination of input cutting parameters for stable turning with improved metal removal rate. Chatter signals generated during the turning of Al6061-T6 have been acquired using a microphone. Stability lobes diagram has been plotted to access the stability regime. Further, to study the effect of feed rate on stability, the recorded signals have been processed using local mean decomposition signal processing technique, followed by the selection of dominating product functions using Fourier transform. The decomposed signals have been used to evaluate the new output parameter, that is, chatter index. Prediction models of chatter index and metal removal rate have been developed. Moreover, these prediction models have been optimized using multi-objective genetic algorithm for ascertaining the optimal range of cutting parameters for stable turning with higher metal removal rate. Finally, obtained stable range has been validated by performing more experiments.

show abstract

“…The existence of self-excited vibration has been proved by several researchers in the past. [26][27][28][29] Wavy profile develops due to the inhomogeneous nature of the work material. This regeneration of wavy profile gives birth to regenerative chatter, which is the most destructive among all other vibrations.…”

Section: CImentioning

confidence: 99%

Analyzing chatter vibration during turning on computer numerical control lathe using ensemble local mean decomposition and probabilistic approach

Gupta

Singh

2021

Noise & Vibration Worldwide

View full text Add to dashboard Cite

Chatter vibration is an undesired and indispensable phenomenon in turning operation, which cannot be completely avoided. However, it can be suppressed by early identification and with the proper choice of input turning parameters. The key issue of chatter detection is to process the acquired signals and extract the features pertaining to it. In the present work, a methodology has been proposed for exploring tool chatter features in the incipient stage during turning on lathe. Chatter signals generated during the turning of Al 6061-T6 have been acquired using a microphone. A stability lobe diagram has been plotted to access the stability regime. Further, in order to study the effect of feed rate on stability, the recorded signals have been processed using a local mean decomposition signal processing technique, followed by the selection of dominating product functions using the Fourier transform. The decomposed signals have been used to evaluate the new output parameter, that is, chatter index. Further, the Nakagami probability distribution has been used to ascertain stability region (threshold). From the experimental validation, it has been inferred that cutting combinations obtained from the Nakagami probability distribution are significant and capable of limiting chatter vibrations. The present methodology will serve as guidelines to the researchers and machinist for the identification of tool chatter in the incipient stage, explore its severity, and finally suppress it with the proper selection of input turning parameters.

show abstract

The Effect of Flexible-Tool Rotation on Regenerative Instability in Machining

Cited by 27 publications

References 19 publications

Integrated Structural/Control Design of Micro-Positioner for Boring Bar Tool Insert

Integrated Structural/Control Design of Micro-Positioner for Boring Bar Tool Insert

Ensembled local mean decomposition and genetic algorithm approach to investigate tool chatter features at higher metal removal rate

Analyzing chatter vibration during turning on computer numerical control lathe using ensemble local mean decomposition and probabilistic approach

Contact Info

Product

Resources

About