Vibrations and Surface Generation in Slab Milling

Heisel, Uwe; Milberg, J.

doi:10.1016/s0007-8506(07)62226-4

Cited by 23 publications

(9 citation statements)

References 12 publications

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“…It was generally accepted that wave patterns left on the work piece from a previous pass greatly effects the current pass, however, it is demonstrated that tool passes two or more turns prior to the current pass also have an effect. The phase difference and frequency of the waves etched into the surface of the prior turns interact with one another, and if the conditions are correct, interact in a critical way that produces increasing amplitude vibrations [16]. While Tlusty was able to theorize that chatter stabilizes at a certain point due to the tool leaving the work piece, Kondo et al set off to prove this theory [15].…”

Section: Literature Reviewmentioning

confidence: 99%

Numerical and experimental modal analysis of machine tool spindles accounting for system decay and its application to chatter avoidance.

Gaber¹

2021

Preprint

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Cycle time, which is the time it takes to machine a certain part, has undergone a great deal of scrutiny as it is directly related to a company's profitability. When trying to machine a part as quickly as possible, selecting the wrong cutting parameters will cause chatter. Tight surface finish and thickness tolerances are usually required by customers. Money lost due to rework and scrap from the destructive nature of chatter has driven a significant number of research studies. It is well established that chatter is directly linked to the natural frequency of the cutting system. As the spindle ages, the vibrational characteristics of the system change. The wear in the spindle bearings causes the system stiffness to decline which results in the changing of natural frequency changing. This change causes the stability lobes to shift. This shift could render a usually stable cut unstable, causing poor surface finish. Excessive chatter can also damage the spindle and shorten its usable life. The objective of this study is to predict the vibrational behaviour of a spindle as it ages. This will be done for spindles utilized under different production constraints. A model of the spindle is also developed by exploiting its Dynamic Stiffness Matrix (DSM) and applying the proper boundary conditions. These results will then be compared to the experimental results obtained from tap testing different spindles to validate and tune the model. Once the static (non-spinning) results are confirmed and the spindle model tuned to represent the real system, the DSM formulation will then be extended to include varying rotational speeds and relevant boundary condition for further modelling purposes. Ultimately, the goal of this research is to develop a procedure to be able to select the correct cutting parameters over the life cycle of the spindle while minimizing the number of tap tests done on the spindle.

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Section: Literature Reviewmentioning

confidence: 99%

Numerical and experimental modal analysis of machine tool spindles accounting for system decay and its application to chatter avoidance.

Gaber¹

2021

Preprint

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“…Assuming the simple harmonic motion, the form of u ( z, t ) = U ( z ) sinωt, and v ( z, t ) = V ( z ) cosωt (10) where ω frequency of oscillation and U and V are the amplitudes of u and v . Substituting equations (10) into equations (6) and 7, they can be re-written as:…”

Section: Mathematical Modelmentioning

confidence: 99%

“…It was generally accepted that wave patterns left on the work piece from a previous pass greatly effects the current pass, however, it is demonstrated that tool passes two or more turns prior to the current also have an effect. The phase difference and frequency of the waves etched into the surface of the prior turns interact with one another, and if the conditions are correct, interact in a critical way that produces increasing amplitude vibrations [10]. While Tlusty was able to theorize that chatter stabilizes at a certain point due to the tool leaving the work piece, [12] set off to prove this theory.…”

Section: Introductionmentioning

confidence: 99%

Free Vibration Analysis of Spinning Spindles: A Calibrated Dynamic Stiffness Matrix Method

Hashemi¹,

Gaber²

2012

Advances in Vibration Engineering and Structural Dynamics

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“…Prior research reported that the RMS values reveal a strong correlation between cutting conditions and signals in micro-cutting at sub-micrometer scales. [8,9] Therefore, the AE signals were converted to RMS values. Fig.2 shows a schematic of the experimental method and procedure.…”

Section: Experimental Cutting Conditionsmentioning

confidence: 99%

Characteristic Cutting Signals for Machined Surface Condition Monitoring in Micro milling Processes

Jang¹,

Jang²,

Kim³

et al. 2011

AIP Conference Proceedings

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The demands of mechanical precision micro machining technology have increased due to the need for micro scale precision shapes and parts in biotechnology, optics, and machinery. In the micro-machining process, the machining parameters must be controlled in order to improve the precision and quality of machined parts. Improvements must be made in exclusive precision machining and extensive study of machining technology must be conducted in order to overcome current challenges in the micro machining process. This paper investigates the correlation between the machined surface condition and acoustic emission(AE) signals characterized according to the cutting conditions in the miro-machining process. Micro end mills (200 ㎛ diameter) and an air turbine spindle (120,000rpm) were used machine aluminum 6061-T6. The characteristics of the AE parameters were extracted in order to monitor the condition of the machined surface texture in micro milling process.

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Vibrations and Surface Generation in Slab Milling

Cited by 23 publications

References 12 publications

Numerical and experimental modal analysis of machine tool spindles accounting for system decay and its application to chatter avoidance.

Numerical and experimental modal analysis of machine tool spindles accounting for system decay and its application to chatter avoidance.

Free Vibration Analysis of Spinning Spindles: A Calibrated Dynamic Stiffness Matrix Method

Characteristic Cutting Signals for Machined Surface Condition Monitoring in Micro milling Processes

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