scholarly journals Development of Novel Anisotropic Boring Tool for Chatter Suppression

Procedia CIRP ◽  
2012 ◽  
Vol 1 ◽  
pp. 56-59 ◽  
Author(s):  
Norikazu Suzuki ◽  
Kohei Nishimura ◽  
Ryo Watanabe ◽  
Takashi Kato ◽  
Eiji Shamoto
Keyword(s):  
Chatter Suppression ◽  
Boring Tool

Boring Tool Permitting Scratch-Free Removal

2020 ◽  
Vol 40 (8) ◽  
pp. 681-682
Author(s):  
G. S. Zheleznov ◽  
A. V. Shirokov
Keyword(s):  
Boring Tool

scholarly journals Optimum Selection of Variable Pitch for Chatter Suppression in Face Milling Operations

Materials ◽  
2018 ◽  
Vol 12 (1) ◽  
pp. 112 ◽  
Author(s):  
Alex Iglesias ◽  
Zoltan Dombovari ◽  
German Gonzalez ◽  
Jokin Munoa ◽  
Gabor Stepan
Keyword(s):  
Removal Rate ◽  
Face Milling ◽  
Heavy Duty ◽  
Variable Pitch ◽  
Thin Walls ◽  
Chatter Suppression ◽  
Milling Operations ◽  
Optimum Selection ◽  
Cutting Capacity ◽  
Selection Of

Cutting capacity can be seriously limited in heavy duty face milling processes due to self-excited structural vibrations. Special geometry tools and, specifically, variable pitch milling tools have been extensively used in aeronautic applications with the purpose of removing these detrimental chatter vibrations, where high frequency chatter related to slender tools or thin walls limits productivity. However, the application of this technique in heavy duty face milling operations has not been thoroughly explored. In this paper, a method for the definition of the optimum angles between inserts is presented, based on the optimum pitch angle and the stabilizability diagrams. These diagrams are obtained through the brute force (BF) iterative method, which basically consists of an iterative maximization of the stability by using the semidiscretization method. From the observed results, hints for the selection of the optimum pitch pattern and the optimum values of the angles between inserts are presented. A practical application is implemented and the cutting performance when using an optimized variable pitch tool is assessed. It is concluded that with an optimum selection of the pitch, the material removal rate can be improved up to three times. Finally, the existence of two more different stability lobe families related to the saddle-node and flip type stability losses is demonstrated.

Numerical investigation of chatter suppression in milling using active fixtures in open-loop control

2016 ◽  
Vol 24 (9) ◽  
pp. 1757-1773 ◽  
Author(s):  
Lorenzo Sallese ◽  
Niccolò Grossi ◽  
Antonio Scippa ◽  
Gianni Campatelli
Keyword(s):  
Numerical Investigation ◽  
Removal Rate ◽  
Active Vibration Control ◽  
Open Loop ◽  
Influential Factors ◽  
Depth Of Cut ◽  
Control Logic ◽  
Loop Control ◽  
Testing Environment ◽  
Chatter Suppression

Among the chatter suppression techniques in milling, active fixtures seem to be the most industrially oriented, mainly because these devices could be directly retrofittable to a variety of machine tools. The actual performances strongly depend on fixture design and the control logic employed. The usual approach in the literature, derived from general active vibration control applications, is based on the employment of adaptive closed-loop controls aimed at mitigating the amplitude of chatter frequencies with targeted counteracting vibrations. Whilst this approach has proven its effectiveness, a general application would demand a wide actuation bandwidth that is practically impeded by inertial forces and actuator-related issues. This paper presents the study of the performance of alternative open-loop actuation strategies in suppressing chatter phenomena, aiming at limiting the required actuation bandwidth. A dedicated time-domain simulation model, integrating fixture dynamics and the features of piezoelectric actuators, is developed and experimentally validated in order to be used as a testing environment to assess the effectiveness of the proposed actuation strategies. An extensive numerical investigation is then carried out to highlight the most influential factors in assessing the capability of suppressing chatter vibrations. The results clearly demonstrated that the regenerative effect could be effectively disrupted by actuation frequencies close to half the tooth-pass frequency, as long as adequate displacement is provided by the actuators. This could sensibly increase the critical axial depth of cut and hence improve the achievable material removal rate, as discussed in the paper.

Discrete Time-Delay Optimal Control Method for Experimental Active Chatter Suppression and Its Closed-Loop Stability Analysis

2019 ◽  
Vol 141 (5) ◽  
Author(s):  
Xingwu Zhang ◽  
Ziyu Yin ◽  
Jiawei Gao ◽  
Jinxin Liu ◽  
Robert X. Gao ◽  
...  
Keyword(s):  
Optimal Control ◽  
Closed Loop ◽  
Control Method ◽  
Trial And Error ◽  
Stability Lobe Diagram ◽  
Weighting Matrix ◽  
Chatter Suppression ◽  
Stability Lobe ◽  
Optimal Control Method ◽  
Discrete Time Delay

Chatter is a self-excited and unstable vibration phenomenon during machining operations, which affects the workpiece surface quality and the production efficiency. Active chatter control has been intensively studied to mitigate chatter and expand the boundary of machining stability. This paper presents a discrete time-delay optimal control method for chatter suppression. A dynamical model incorporating the time-periodic and time-delayed characteristic of active chatter suppression during the milling process is first formulated. Next, the milling system is represented as a discrete linear time-invariant (LTI) system with state-space description through averaging and discretization. An optimal control strategy is then formulated to stabilize unstable cutting states, where the balanced realization method is applied to determine the weighting matrix without trial and error. Finally, a closed-loop stability lobe diagram (CLSLD) is proposed to evaluate the performance of the designed controller based on the proposed method. The CLSLD can provide the stability lobe diagram with control and evaluate the performance and robustness of the controller cross the tested spindle speeds. Through many numerical simulations and experimental studies, it demonstrates that the proposed control method can make the unstable cutting parameters stable with control on, reduce the control force to 21% of traditional weighting matrix selection method by trial and error in simulation, and reduce the amplitude of chatter frequency up to 78.6% in experiment. Hence, the designed controller reduces the performance requirements of actuators during active chatter suppression.

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