Surface location error prediction and stability analysis of micro-milling with variation of tool overhang length

Chatter is an undesirable dynamic phenomenon in machining processes, which causes cutting disturbance, overcut, quick tool wear, etc., and thus seriously impairs workpiece quality. To mitigate chatter, traditional methods called passive control focus on optimizing working spindle speeds and depths of cut. But they have inherent disadvantages in gaining highly efficient machining. On the contrary, the research in this paper is along the line of active control. Specifically, an adaptive algorithm is developed based on Fourier series analysis to deal with the so-called regenerative cutting force which causes chatter. As a result, chatter is remarkably mitigated. The performance improvement is illustrated by numerical simulation in terms of both stability lobes diagram (SLD) and surface location error (SLE).

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Prediction of cumulative surface location error at the contact zone of in-process workpiece and milling tool

International Journal of Mechanical Sciences ◽

10.1016/j.ijmecsci.2020.105543 ◽

2020 ◽

Vol 177 ◽

pp. 105543 ◽

Cited By ~ 1

Author(s):

Dongqian Wang ◽

Michael Löser ◽

Yunhu Luo ◽

Steffen Ihlenfeldt ◽

Xibin Wang ◽

...

Keyword(s):

Contact Zone ◽

Location Error ◽

Surface Location Error ◽

Milling Tool ◽

Surface Location

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Assessment of Friction Behavior with Surface Location Error Analysis in Milling Process

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.823.129 ◽

2019 ◽

Vol 823 ◽

pp. 129-134

Author(s):

N.A. Rafan ◽

Siti Nur Madihah Ab Rashid ◽

Z. Jamaludin

Keyword(s):

Manufacturing Industry ◽

Milling Process ◽

Work Piece ◽

Location Error ◽

Friction Behavior ◽

Error Location ◽

Surface Location Error ◽

Highly Nonlinear ◽

Important Quality ◽

Surface Location

Accurate roundness or circularity measurement is essential to obtain correct functioning of assemblies, making roundness an important quality control parameter in manufacturing industry. Since circular motion while milling a circular work piece leads to quadrant glitches, a phenomenon familiar with existence of highly nonlinear friction behavior, roundness measurement was conducted to investigate this surface location error due to feed rate of the moving work table. This paper presents friction behavior on a milling process circular work piece in line resulted from identified surface error location (SLE).

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Chatter stability and surface location error predictions in milling with mode coupling and process damping

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/0954405417708225 ◽

2017 ◽

Vol 233 (3) ◽

pp. 686-698 ◽

Cited By ~ 12

Author(s):

Zhongyun Li ◽

Shanglei Jiang ◽

Yuwen Sun

Keyword(s):

Dynamic Model ◽

Mode Coupling ◽

Vital Role ◽

Milling Process ◽

Location Error ◽

Process Damping ◽

Stability Lobes ◽

Surface Location Error ◽

Surface Location ◽

Extended Dynamic

Together with machining chatter, surface location error induced by forced vibration may also inhibit productivity and affect workpiece surface quality in milling process. Addressing these issues needs the combined consideration of stability lobes diagram and surface location error predictions. However, mode coupling and process damping are seldom taken into consideration. In this article, an extended dynamic milling model including mode coupling and process damping is first built based on classical 2-degree-of-freedom dynamic model with regeneration. Then, a second-order semi-discretization method is proposed to simultaneously predict the stability lobes diagram and surface location error by solving this extended dynamic model. The rate of convergence of the proposed method is also investigated. Finally, a series of experiments are conducted to verify the veracity of the extended dynamic model. The modal parameters including direct and cross terms are identified by impact experiments. Via experimental verification, the experimental results show a good correlation with the predicted stability lobes diagram and surface location error based on the extended dynamic model. Also, the effects of mode coupling and process damping are revealed. Mode coupling increases the whole stability region; however, process damping plays a vital role in stability improvement mainly at low spindle speeds.

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