Milling stability analysis using the spectral method

Stability analysis is needed to maximize milling performance while avoiding chatter. However, such an analysis is time-consuming, requiring the use of sophisticated instrumentation, and has significant level of uncertainty, which impedes the widespread use by industry. A main source of uncertainty is believed to be the changes in dynamics of the tool-holder-spindle system during the milling operation. This study investigates the variation in the tool point dynamics reflecting the dynamics of the tool-holder-spindle system and associated machining stability. The investigation focuses on the effects of the conditions generated by typical milling operations, such as tool changes and spindle warm up. The results of analyses demonstrate the necessity of continuous updates of the tool point dynamics during milling process by in-situ measurements to minimize uncertainty in evaluation of machining stability.

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On a solenoidal Fourier–Chebyshev spectral method for stability analysis of the Hagen–Poiseuille flow

Applied Numerical Mathematics ◽

10.1016/j.apnum.2006.09.002 ◽

2007 ◽

Vol 57 (8) ◽

pp. 920-938 ◽

Cited By ~ 22

Author(s):

A. Meseguer ◽

F. Mellibovsky

Keyword(s):

Stability Analysis ◽

Spectral Method ◽

Poiseuille Flow ◽

Chebyshev Spectral Method

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Linear stability analysis of thermocapillary convection in liquid bridges using a mixed finite difference‐spectral method

International Journal of Numerical Methods for Heat &amp Fluid Flow ◽

10.1108/eum0000000004074 ◽

1995 ◽

Vol 5 (6) ◽

pp. 481-494 ◽

Cited By ~ 2

Author(s):

J.–C. Chen ◽

S.–S. Sheu

Keyword(s):

Stability Analysis ◽

Finite Difference ◽

Spectral Method ◽

Linear Stability ◽

Linear Stability Analysis ◽

Thermocapillary Convection ◽

Liquid Bridges

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Stability analysis in milling of thin-walled workpieces with emphasis on the structural effect

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

10.1243/09544054jem1696 ◽

2009 ◽

Vol 224 (4) ◽

pp. 589-608 ◽

Cited By ~ 12

Author(s):

X-J Zhang ◽

C-H Xiong ◽

Y Ding ◽

X-M Zhang

Keyword(s):

Stability Analysis ◽

Great Influence ◽

Structural Effect ◽

Experimental Results ◽

Machining Parameters ◽

Chatter Stability ◽

Milling Stability ◽

Thin Walled ◽

Five Axis ◽

Milling Chatter

Regenerative chatter easily occurs in milling and has become the common limitation to achieve good surface quality and high productivity. For the purpose of chatter avoidance, the structural effect of the thin-walled part should be considered for the milling chatter stability analysis for the optimization of axial cutting depth and spindle speed pairs. The main objective of this paper is to examine the link between the structural modes (i.e. modal shapes) and the chatter stability limits in the case of finish milling thin-walled workpieces. In this paper, the dynamic stability of the milling process of thin-walled workpieces is investigated through a two-degree-of-freedom mechanical model. The mathematical relationship between the critical axial depth and the thin-walled part modal shapes is deduced and an optimal calculation process of milling stability lobes is presented. Peripheral milling of aluminium alloy (2A70 Al) plates is carried out on a computer numerically controlled (CNC) five-axis super high-speed machining centre to validate the method. The experimental results agree with the prediction by the presented method. Additionally, the experimental results show that the cutting stability is also influenced by the modal frequencies of the thin-walled part, which have a great influence on the milling stability analysis when the tool passing frequency (i.e. the inverse of the tooth passing period) harmonics are close to the modal frequencies of the part. The presented method is effective in the prediction of milling chatter limits in the thin-walled case for the optimization of machining parameters.

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