Machining Chatter Analysis for High Speed Milling Operations

High-speed milling is often used in industry to maximize productivity of the manufacturing of high-technology components, such as aeronautical components, mold, and dies. The occurrence of chatter highly limits the efficiency and accuracy of high-speed milling operations. In this paper, two control strategies are presented that guarantee a chatter-free high-speed milling operation by automatic adaptation of spindle speed and feed. Moreover, the proposed strategies are robust for changing process conditions (e.g., due to heating of the spindle or tool wear). An important part of the control strategy is the detection of chatter. A novel chatter detection algorithm is presented that automatically detects chatter in an online fashion and in a premature phase such that no visible marks on the workpiece are present. Experiments on a state-of-the-art high-speed milling machine underline the effectiveness of the proposed detection and control strategies.

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Chatter Stability Prediction in High Speed Milling Considering Multi-Degree of Freedom

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.431-432.373 ◽

2010 ◽

Vol 431-432 ◽

pp. 373-376

Author(s):

Shan Shan Sun ◽

Wei Xiao Tang ◽

Xi Qing Xu

Keyword(s):

High Speed ◽

Spindle Speed ◽

Depth Of Cut ◽

Machining Parameters ◽

Stability Prediction ◽

High Speed Milling ◽

Stability Lobes ◽

Milling Operations ◽

Critical Requirement ◽

Multi Mode

Chatter problems occurring during high speed milling affect the quality of the finished workpiece and, to a lesser extent, the tool life and the spindle life. Therefore, the prediction of stable milling regions is a critical requirement for high speed milling operations. In this paper, a dynamic model of a high speed spindle system considering the multi-mode dynamics is elaborated for the purposed of stability prediction. A stability lobes diagram (SLD) shows the boundary between chatter-free machining operations and unstable processes, in terms of axial depth of cut as a function of spindle speed. These diagrams are used to select chatter-free combinations of machining parameters. The proposed method enables a new stability lobes diagram to be established that takes into account the effect of spindle speed on multi-mode dynamic behavior.

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Requirements for Consistent and Productive Performance in High Speed Milling

Manufacturing ◽

10.1115/imece2003-41694 ◽

2003 ◽

Cited By ~ 1

Author(s):

Keith A. Young ◽

Amy M. Helvey

Keyword(s):

High Speed ◽

Productive Performance ◽

High Speed Milling ◽

Milling Operations ◽

Performance Constraint ◽

Tool Chatter

The major performance constraint in high speed milling operations is tool chatter. This is especially true when using long slender tools. Much recent research has been done to improve the performance of milling operations through choosing tool lengths and spindle speeds such that tool chatter is avoided. This paper describes two criteria for choosing productive lengths of tools.

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Laser Polishing Operation for Die and Moulds Finishing

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.83-86.818 ◽

2009 ◽

Vol 83-86 ◽

pp. 818-825 ◽

Cited By ~ 3

Author(s):

Eneko Ukar ◽

Aitzol Lamikiz ◽

Luis Norberto López de Lacalle ◽

F. Liebana ◽

J.M. Etayo ◽

...

Keyword(s):

Laser Beam ◽

High Speed ◽

Input Data ◽

Diode Lasers ◽

Experimental Tests ◽

High Speed Milling ◽

Laser Polishing ◽

Milling Operations ◽

Operation Parameters ◽

Power Diode

The presented article proposes a laser based polishing operation which consists in the application of a laser beam in a very controlled way. The work presents several polishing tests carried out with CO2 and High Power Diode Lasers, for a DIN 1.2379 tool steel tempered up to 62HRC. This material is commonly used for injection moulds and inserts for stamping dies. The Laser Polishing tests results have been used as the input data for a design of experiments (DoE), therefore the optimum operation parameters for the process as well as its degree of influence in the melted surface have been defined. Experimental tests have been performed from different initial roughness values obtained by High Speed Milling operations. Reductions of final roughness higher than 80% have been obtained with respect to the initial roughness, with values below 0.8μm Ra.

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A Mathematical Model of EEBP for HSM Surface Quality Prediction

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.97-101.2123 ◽

2010 ◽

Vol 97-101 ◽

pp. 2123-2127 ◽

Cited By ~ 1

Author(s):

Yue En Li ◽

Jun Zhao ◽

W. Wang ◽

Q.Y. Cao

Keyword(s):

Surface Quality ◽

High Speed ◽

Cutting Parameters ◽

Machined Surface ◽

High Speed Milling ◽

Milling Operations ◽

Milling Operation ◽

Machined Parts ◽

Roughness Prediction ◽

Optimal Cutting Parameters

The main purpose of this study was to construct a relationship between the cutting parameters and the machined surface on high speed milling operation. An optimization algorithm using an Exponential Equation and BP method (EEBP) is then applied to determine optimal cutting parameters. For using the method, once the material removal volumes for machined parts of the high speed milling operations are given, the surface quality could be predicted. The final result we choose the surface roughness prediction as an example of H13 dies steel HSM in this paper, it presents that the method is efficient and feasible.

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Control of Chatter by Spindle Speed Variation in High-Speed Milling

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.112.179 ◽

2010 ◽

Vol 112 ◽

pp. 179-186 ◽

Cited By ~ 8

Author(s):

Sébastien Seguy ◽

Gilles Dessein ◽

Lionel Arnaud ◽

Tamás Insperger

Keyword(s):

High Speed ◽

Spindle Speed ◽

High Speed Milling ◽

Speed Variation ◽

Milling Operations ◽

Spindle Speed Variation ◽

Machine Tool Chatter ◽

Parametric Studies ◽

Sinusoidal Shape ◽

The Stability

High-speed milling operations are often limited by regenerative vibrations. The aim of this paper is to analyze the effect of spindle speed variation on machine tool chatter in high-speed milling. The stability analysis of triangular and sinusoidal shape variations is made numerically with the semi-discretization method. Parametric studies show also the influence of the frequency and amplitude variation parameters. This modeling is validated experimentally by variable spindle speed cutting tests with a triangular shape. Stable and unstable tests are analyzed in term of amplitude vibration and surface roughness degradation. This work reveals that stability must be considered at period variation scale. It is also shown that spindle speed variation can be efficiently used to suppress chatter in the flip lobe area.

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