scholarly journals Chatter Stability Prediction Method of the Spindle-Tool Holder-Tool System with Interface Contact Characteristics

2020 ◽  
Vol 2020 ◽  
pp. 1-15
Author(s):  
Li Cui ◽  
Yin Su
Keyword(s):  
Cutting Force ◽  
Prediction Method ◽  
Chatter Stability ◽  
Chatter Vibration ◽  
Cutting Depth ◽  
Milling Stability ◽  
Tool Holder ◽  
Interface Dynamic ◽  
Interface Contact ◽  
Chatter Stability Prediction

To predict chatter stability and suppress chatter vibration, a chatter stability prediction method for the spindle-tool holder-tool system with interface contact characteristics is constructed. A five-DOF model is constructed to determine the spindle-bearing interface dynamic contact stiffness considering the coupling effect of spindle and bearing. A fractal multiscale tool holder-spindle interface dynamic stiffness model is proposed considering time-varying cutting force. The fractal dimensions and cutting force coefficient parameters are identified from the power spectrum experiments and cutting force tests. The cutting force is solved according to the milling stability model. Dynamic model of the spindle-tool holder-tool system is found by the finite element method. Based on extended Floquet theory, chatter stability of the spindle system is studied. Effect of interface parameters, radial cutting depth, and feed rate on milling stability is researched. Milling force tests and milling stability tests are performed in order to verify the reliability of the method. Results find that the increase of front bearing preload and spindle-tool holder’s interference fit are effective to improve the milling stability. The optimal feed rate and the critical radial cutting depth are found. The model proposed in this paper can be used as an instruction for predicting and suppressing the chatter vibration and optimizing cutting parameters and also is helpful for designing the spindle-tool holder-tool system.

scholarly journals Robust Chatter Stability Prediction of the Milling Process considering Uncertain Machining Positions

2020 ◽  
Vol 2020 ◽  
pp. 1-15
Author(s):  
Congying Deng ◽  
Wei Zhou ◽  
Kai Yang ◽  
Zhiyu Huang ◽  
Qian Tang
Keyword(s):  
Prediction Method ◽  
Modal Parameters ◽  
Stability Prediction ◽  
Chatter Stability ◽  
Milling Stability ◽  
Machining Allowance ◽  
Machining Parameter ◽  
Milling Chatter ◽  
Edge Theorem ◽  
Chatter Stability Prediction

Milling stability is a function of the tool point frequency response functions (FRFs), which vary with the movements of the moving parts within the whole machine tool work volume. The position-dependent tool point FRFs result in uncertain prediction of the stability lobe diagram (SLD) for chatter-free machining parameter selection. Taking the variations of modal parameters to represent the variations of tool point FRFs, this paper introduces the edge theorem to predict the robust milling chatter stability. The application of the edge theorem requires the minimum and maximum modal parameters within the machining space defined by the machining position and machining allowance information. Then, radial basis function artificial neural networks (RBFANNs) are used to predict the position-dependent modal parameters in X and Y directions based on the sample information of machining positions and related modal parameters at the tool point. Moreover, sample machining spaces are determined based on the aforementioned sample positions, and the trained RBFANNs are used to obtain corresponding sample extreme modal parameters. On this basis, RBFANNs for predicting the position and machining allowance-dependent extreme modal parameters can also be trained, and they are combined with the edge theorem and zero exclusion condition to calculate robust pairs of the spindle speed (n) and limiting axial cutting depth (aplim) and then plot the robust SLD (RSLD). A case study was performed on a real three-axial vertical machining center, and the plotted RSLD considering position variations was compared with the traditional SLD. Results of the chatter tests show that the RSLD can provide more reliable (ap, n) pairs to guarantee the milling stability, validating the feasibility of the proposed robust milling chatter stability prediction method.

Chatter stability prediction of milling considering nonlinearities

2020 ◽  
pp. 095440542097107
Author(s):  
Yiqing Yang ◽  
Donghui Wu ◽  
Qiang Liu
Keyword(s):  
Cutting Force ◽  
Time Domain ◽  
Cutting Speed ◽  
Dissipated Energy ◽  
Stability Prediction ◽  
Chatter Stability ◽  
Process Damping ◽  
Stability Lobes ◽  
The Time Domain ◽  
Chatter Stability Prediction

Nonlinearities have been evidenced during the chatter vibration of milling. Machinability of the thin-walled part is feed rate and position-dependent, and is subject to process damping at low cutting speed. Therefore, chatter stability prediction of milling considering nonlinear cutting force, nonlinear structural stiffness and process damping is investigated. The cutting force and stiffness are established based on the polynomial model and the process damping is investigated based on the dissipated energy. The dynamic cutting force and stability lobes are solved in the time domain with coefficients updated at each iteration. By formulating the displacement as an expanded form via the perturbation method, the time-consuming solution of delay differential equations is avoided. After formulating the identification of the nonlinear model via cutting tests and modal tests, numerical simulations considering nonlinearities are carried out and compared with the analytical method. The proposed method attains high accuracy of classic time-domain solution, but with an improved computational efficiency. Finally, cutting tests are conducted to verify the prediction of cutting force and stability lobes.

Prediction of Regeneration Chatter Stability of Composite Boring Bar

2019 ◽  
Vol 295 ◽  
pp. 73-83
Author(s):  
Yong Sheng Ren ◽  
Ji Shuang Tian ◽  
Yu Huan Zhang ◽  
Jing Min Ma
Keyword(s):  
Dynamic Stiffness ◽  
Stability Boundary ◽  
Structural Damping ◽  
Chatter Stability ◽  
Cutting Depth ◽  
Boring Bar ◽  
Critical Cutting Depth ◽  
Time Domain Response ◽  
Euler Bernoulli Beam ◽  
Chatter Stability Prediction

The deep holes cutting process by metal boring bar is usually limited due to the development of chatter vibration. This is because metal boring bar has not only low bending stiffness but also low structural damping. A chatter stability prediction of composite boring bar under regenerative cutting force is presented. Based on the theory of Euler-Bernoulli beam, the regenerative chatter dynamic model of composite boring bar is proposed, and the solution formula of the limited cutting depth and corresponding spindle speed is given. The dynamic stability lobes of the composite boring bar are obtained by numerical calculation. The results indicate that composite boring bar exhibits efficient chatter stability than metal boring bar. Chatter stability is closely related to fiber ply angle. It is demonstrated that when ply angle is 0o, carbon/ epoxy reaches its critical cutting depth, and for graphite/ epoxy boring bar about 25o of ply angle gives its critical cutting depth, It is also demonstrated that stability boundary decreases as the ratio length and diameter increases. Finally, the prediction results of stability are compared with those from the dynamic stiffness and time-domain response, agreement is found.

Research on Milling Stability Using CNC Small Size Tool

2011 ◽  
Vol 199-200 ◽  
pp. 1993-1998
Author(s):  
Yong Xin Luo ◽  
Xiao Long Shen ◽  
Hua Long ◽  
Lai Xi Zhang
Keyword(s):  
Manufacturing System ◽  
Stability Domain ◽  
Mining Machine ◽  
Cnc Milling ◽  
Chatter Stability ◽  
Cutting Depth ◽  
Milling Stability ◽  
Cnc Milling Machine ◽  
The Stability ◽  
Milling Chatter

In a larger-power CNC milling machine, the milling stability of CNC small size tool which is less than φ 25 diameters is restricted under a certain degree. Authors studied CNC milling chatter stability by the experiment and simulation; they had researched those influences of tool’s diameter, suspended length and craft of manufacturing system on chatter stability domain. Researches show that the larger diameter and shorter suspended length of the tool can improve the stability of milling, and also can improve critical axial cutting depth. The lobes of chatter stability domain can forecast effectively critical axial cutting depth and relevant to milling speed, can better mining machine cutting potential.

Three-axial cutting force measurement in micro/nano-cutting by utilizing a fast tool servo with a smart tool holder

CIRP Annals ◽  
2021 ◽  
Author(s):  
Yuan-Liu Chen ◽  
Fuwen Chen ◽  
Zhongwei Li ◽  
Yang Zhang ◽  
Bingfeng Ju ◽  
...  
Keyword(s):  
Cutting Force ◽  
Force Measurement ◽  
Fast Tool Servo ◽  
Tool Holder ◽  
Cutting Force Measurement

Identification of Dynamical Contact Parameters for Spindle-Tool Holder Interface Based on the Receptance Coupling Substructure Approach

2011 ◽  
Vol 287-290 ◽  
pp. 2185-2190
Author(s):  
Yong Sheng Zhao ◽  
Ri Qing Dong ◽  
Zhi Feng Liu ◽  
Tie Neng Guo
Keyword(s):  
Contact Dynamics ◽  
Chatter Stability ◽  
Simple Manner ◽  
Accurate Identification ◽  
Tool Holder ◽  
Receptance Coupling ◽  
Dynamical Parameters ◽  
Substructure Approach ◽  
Stiffness And Damping ◽  
Contact Parameters

It is very crucial to accurately identify the parameters of contact dynamics in predicting the chatter stability of spindle–tool holder assemblies in machining centers. Fast and accurate identification of contact dynamics in spindle–tool holder assembly has become an important issue in the recent years. In this paper, the receptance coupling substructure approach is employed for identification the stiffness and damping of the interface in a simple manner, in which the frequency response function of the tool holder is derived from the Timoshenko beam finite elements model. A BT 50 type tool holder is adopted as an application example of the method. Although this study focuses on the contact dynamics at the spindle–tool holder interfaces of the assembly, the approach might be used for identifying the dynamical parameters of other critical interface.

An Experimental Study of Cutting Force on Large Cutting Depth Turning Titanium Alloy with CBN Tool

2014 ◽  
Vol 800-801 ◽  
pp. 237-240
Author(s):  
Li Fu Xu ◽  
Ze Liang Wang ◽  
Shu Tao Huang ◽  
Bao Lin Dai
Keyword(s):  
Experimental Study ◽  
Titanium Alloy ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Depth ◽  
Cbn Tool ◽  
Cutting Experiment ◽  
Rough Turning

In this paper, the cutting experiment was used to study the influence of various cutting parameters on cutting force when rough turning titanium alloy (TC4) with the whole CBN tool. The results indicate that among the cutting speed, feed rate and cutting depth, the influence of the cutting depth is the most significant on cutting force; the next is the feed rate and the cutting speed is at least.

Molecular Dynamics Study on the Impact of the Cutting Depth to the Titanium Nanometric Cutting

2014 ◽  
Vol 536-537 ◽  
pp. 1431-1434 ◽  
Author(s):  
Ying Zhu ◽  
Yin Cheng Zhang ◽  
Shun He Qi ◽  
Zhi Xiang
Keyword(s):  
Molecular Dynamics ◽  
Potential Energy ◽  
Cutting Force ◽  
Simulation Study ◽  
Cutting Process ◽  
Work Piece ◽  
Cutting Depth ◽  
Nanometric Cutting ◽  
The Impact

Based on the molecular dynamics (MD) theory, in this article, we made a simulation study on titanium nanometric cutting process at different cutting depths, and analyzed the changes of the cutting depth to the effects on the work piece morphology, system potential energy, cutting force and work piece temperature in this titanium nanometric cutting process. The results show that with the increase of the cutting depth, system potential energy, cutting force and work piece temperature will increase correspondingly while the surface quality of machined work piece will decrease.

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