scholarly journals An Improved Receptance Coupling Substructure Analysis to Predict Chatter Free High Speed Cutting Conditions

Procedia CIRP ◽  
2013 ◽  
Vol 12 ◽  
pp. 19-24 ◽  
Author(s):  
P. Albertelli ◽  
M. Goletti ◽  
M. Monno
Keyword(s):  
High Speed ◽  
Cutting Conditions ◽  
High Speed Cutting ◽  
Receptance Coupling ◽  
Substructure Analysis ◽  
Receptance Coupling Substructure Analysis

Three-Component Receptance Coupling Substructure Analysis for Tool Point Dynamics Prediction

2005 ◽  
Vol 127 (4) ◽  
pp. 781-790 ◽  
Author(s):  
Tony L. Schmitz ◽  
G. Scott Duncan
Keyword(s):  
Finite Difference ◽  
High Speed ◽  
Experimental Validation ◽  
Second Generation ◽  
Standard Test ◽  
High Speed Machining ◽  
Receptance Coupling ◽  
Substructure Analysis ◽  
Receptance Coupling Substructure Analysis ◽  
Tool Assembly

In this paper we present the second generation receptance coupling substructure analysis (RCSA) method, which is used to predict the tool point response for high-speed machining applications. This method divides the spindle-holder-tool assembly into three substructures: the spindle-holder base; the extended holder; and the tool. The tool and extended holder receptances are modeled, while the spindle-holder base subassembly receptances are measured using a “standard” test holder and finite difference calculations. To predict the tool point dynamics, RCSA is used to couple the three substructures. Experimental validation is provided.

Tool Point Frequency Response Prediction for High-Speed Machining by RCSA

2001 ◽  
Vol 123 (4) ◽  
pp. 700-707 ◽  
Author(s):  
Tony L. Schmitz ◽  
Matthew A. Davies ◽  
Michael D. Kennedy
Keyword(s):  
Frequency Response ◽  
High Speed ◽  
Response Prediction ◽  
High Speed Machining ◽  
Receptance Coupling ◽  
Substructure Analysis ◽  
Receptance Coupling Substructure Analysis ◽  
Shrink Fit ◽  
Chatter Stability Prediction ◽  
Analytic Prediction

The implementation of high-speed machining for the manufacture of discrete parts requires accurate knowledge of the system dynamics. We describe the application of receptance coupling substructure analysis (RCSA) to the analytic prediction of the tool point dynamic response by combining frequency response measurements of individual components through appropriate connections. Experimental verification of the receptance coupling method for various tool geometries (e.g., diameter and length) and holders (HSK 63A collet and shrink fit) is given. Several experimental results are presented to demonstrate the practical applicability of the proposed method for chatter stability prediction in milling.

Predicting Tool Point FRF by RCSA in High Speed Milling

2014 ◽  
Vol 1006-1007 ◽  
pp. 398-402
Author(s):  
Kun Long Wen ◽  
Hou Jun Qi
Keyword(s):  
High Speed ◽  
Beam Model ◽  
High Speed Milling ◽  
Receptance Coupling ◽  
Substructure Analysis ◽  
Joint Connection ◽  
Machine Spindle ◽  
Receptance Coupling Substructure Analysis ◽  
Tool Shank ◽  
Euler Bernoulli Beam

Tool point frequency response function (FRF) is the key parameters to predict the milling stability in high-speed milling. Receptance coupling substructure analysis (RCSA) is described to predict the tool point FRF. The major difficulties in RCSA are the identification of joint connection parameters and the obtaining of FRFs of substructure. This paper separation of the milling system into three substructures: the machine-spindle-holder taper, the extended holder-tool shank, and the tool extended portion. Develop the connection model compose of linear and rotational springs and dampers. Determine the substructure FRF by measurement and Euler-Bernoulli beam model. Tool point FRF is obtained by coupling the substructure FRFs through the connection model by RCSA.

Receptance Coupling Study of Tool-Length Dependent Dynamic Absorber Effect

2004 ◽  
Author(s):  
Timothy J. Burns ◽  
Tony L. Schmitz
Keyword(s):  
Frequency Response ◽  
High Speed ◽  
Removal Rate ◽  
Stability Lobe ◽  
Receptance Coupling ◽  
Rapid Prediction ◽  
Substructure Analysis ◽  
Dynamic Absorber ◽  
Receptance Coupling Substructure Analysis ◽  
Free Material

The chatter-free material removal rate during high-speed machining of aluminum using long, slender endmills is limited by the cutting system dynamics, which changes with the tool length. Traditional stability-lobe diagrams that predict the maximum allowable chip width for a given spindle speed are determined using the tool point frequency response function. A brief review is given of a combined analytical and experimental method that uses receptance coupling substructure analysis (RCSA) for the rapid prediction of the tool-point frequency response as the tool length is varied. The basic idea of the method is to combine the measured direct displacement vs. force receptance (i.e., frequency response) at the free end of the spindle-holder system with analytical expressions for the tool receptances. The method is then used to provide an explanation for the dynamic absorber effect that has been observed in the context of tool-length tuning.

Finite Element Analysis of Cutting Forces in High Speed Machining

2006 ◽  
Vol 532-533 ◽  
pp. 753-756 ◽  
Author(s):  
Jun Zhao ◽  
Xing Ai ◽  
Zuo Li Li
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Fem Simulation ◽  
Chip Thickness ◽  
Cutting Conditions ◽  
Cutting Process ◽  
Undeformed Chip Thickness ◽  
High Speed Cutting

The Finite Element Method (FEM) has proven to be an effective technique to investigate cutting process so as to improve cutting tool design and select optimum cutting conditions. The present work focuses on the FEM simulation of cutting forces in high speed cutting by using an orthogonal cutting model with variant undeformed chip thickness under plane-strain condition to mimic intermittent cutting process such as milling. High speed cutting of 45%C steel using uncoated carbide tools are simulated as the application of the proposed model. The updated Lagrangian formulation is adopted in the dynamic FEM simulation in which the normalized Cockroft and Latham damage criterion is used as the ductile fracture criterion. The simulation results of cutting force components under different cutting conditions show that both the thrust cutting force and the tangential cutting force increase with the increase in undeformed chip thickness or feed rate, whereas decrease with the increase in cutting speed. Some important aspects of modeling the high speed cutting are discussed as well to expect the future work in FEM simulation.

Investigation for High Speed Ultrasonic Cutting of Aluminum Alloy

2012 ◽  
Vol 516 ◽  
pp. 367-372 ◽  
Author(s):  
Keisuke Hara ◽  
Hiromi Isobe ◽  
Yoshihiro Take ◽  
Toshihiko Koiwa
Keyword(s):  
High Speed ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Ultrasonic Oscillation ◽  
Workpiece Material ◽  
Machined Surface ◽  
High Speed Cutting ◽  
Cemented Carbide Tool ◽  
Cutting Operation ◽  
Ultrasonic Cutting

This study investigated phenomena of ultrasonic cutting in the case of high-speed conditions. Ultrasonically assisted cutting techniques were developed by Kumabe in the 1950s. He found a critical cutting speed that limits cutting speed to obtain ultrasonically assisted effects and is calculated by frequency and amplitude of oscillation. In general, ultrasonically assisted cutting is not suitable for high-speed cutting conditions because the effects of ultrasonic application are cancelled due to tool contacts with the workpiece during the cutting operation. Present ultrasonically assisted cutting cannot allow increased cutting speed because cutting speed is limited by a critical cutting speed that is less than that compared with general cutting speed. And ultrasonically assisted cutting cannot improve productivity due to long processing time. We conducted high-speed ultrasonic cutting, and the maximum cutting speed in this research was 300 m/min which is higher than general critical cutting speed. The workpiece material was A5056 and cemented carbide tool inserts were employed in this research. Without ultrasonic oscillation, machined surface retained some built up edge and surface roughness is 28 μmRz. In the case of ultrasonic cutting, surface hasnt built up edge and periodically marks due to ultrasonic oscillation remained on the surface. The roughness of conventionally cut surface is better than in ultrasonic cutting. The cutting phenomena of ultrasonic cutting are different compared with those under conventional cutting conditions.

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