Active Control of Regenerative Chatter During Metal Cutting Process

2005 ◽  
Vol 128 (1) ◽  
pp. 346-349 ◽  
Author(s):  
C. Mei ◽  
J. G. Cherng ◽  
Y. Wang
Keyword(s):  
Frequency Domain ◽  
Metal Cutting ◽  
Hybrid Approach ◽  
Stability Lobe Diagram ◽  
Regenerative Chatter ◽  
Stability Lobe ◽  
The Stability ◽  
The Many ◽  
Frequency Domain Approach ◽  
Frequent Problem

Chatter, a violent relative vibration between a workpiece and a cutting tool, is a frequent problem in a machining operation. Among the many factors which contribute to the problem, regenerative chatter is found to be the most detrimental. Optimal control is designed for suppressing regenerative chatter with the critical regenerative effect taken into account. Furthermore, a novel hybrid time and frequency domain approach is developed for generating the stability lobe diagram for the dynamic system after control, since the conventional frequency domain approach is no longer feasible. Numerical results are obtained in both time and frequency domain for verifying the effectiveness of the controller as well as the hybrid approach for generating the stability lobe diagram.

Design of a Force Feedback Chatter Control System

1972 ◽  
Vol 94 (1) ◽  
pp. 5-10 ◽  
Author(s):  
C. Nachtigal
Keyword(s):  
Machine Tool ◽  
Frequency Domain ◽  
Transient Response ◽  
Force Feedback ◽  
Design Procedure ◽  
Experimental Tests ◽  
Work Piece ◽  
Regenerative Chatter ◽  
Chatter Control ◽  
The Stability

The analysis of machine tool chatter from frequency domain considerations is generally accepted as a valid representation of the regenerative chatter phenomenon. However, active control of regenerative chatter is still in its embryonic stage. It was established in reference [2] that a measurement of the cutting force could be effectively used in conjunction with a controller and a tool position servo system to increase the stability of an engine lathe and to improve its transient response. This paper presents the design basis for such a system, including both analytical and experimental considerations. The design procedure stems from a real part stability criterion based on the work by Merritt [1]. Because of the unknown variability in the dynamics of a machine tool system, the controller parameters were chosen to accomodate some mismatch between structure and tool servo dynamics. Experimental tests to determine the stability zone of the controlled machine tool system qualitatively confirmed the analytical design results. The experimental results were consistent in that the transient response tests confirmed the frequency domain stability tests. It was also demonstrated experimentally that the equivalent static stiffness of a flexible work-piece system could be substantially increased.

Novel Direct Model for Machining Regenerative Chatter

2016 ◽  
Author(s):  
Aaron Lalley ◽  
Mark Bedillion
Keyword(s):  
Simulation Model ◽  
Machining Process ◽  
Direct Simulation ◽  
Regenerative Chatter ◽  
Stability Lobe ◽  
Direct Model ◽  
Machining Chatter ◽  
The Stability ◽  
Time Information ◽  
New Time

Regenerative machining chatter or resonance in the machining process has traditionally been modeled with the stability lobe approach. This paper presents a new time based direct simulation model and compares it with traditional stability lobe modeling. The direct model has the ability to discriminate directional and time information, resulting in a number of advantages over frequency-based stability lobe analysis.

Data Processing in Bifurcation Analysis of Maps with Time-Delays in the Frequency Domain

2014 ◽  
Vol 685 ◽  
pp. 634-637
Author(s):  
Li Zeng ◽  
Jun Wei Wang
Keyword(s):  
Data Processing ◽  
Frequency Domain ◽  
Time Delays ◽  
Period Doubling ◽  
Feedback Systems ◽  
Bifurcation Solution ◽  
Nonlinear Maps ◽  
The Stability ◽  
Frequency Domain Approach ◽  
Period Doubling Bifurcations

A unified frequency-domain approach to analyze the NS (Neimark-Sacker) bifurcations and the period-doubling bifurcations of nonlinear maps with time-delays in the linear feed-forward term is presented. The technique relies on the HBA (harmonic balance approximation, a very important method in data processing ) and feedback systems theory. The expressions of the bifurcation solution and the stability are derived.

STABILITY AND HOPF BIFURCATION ON A TWO-NEURON SYSTEM WITH TIME DELAY IN THE FREQUENCY DOMAIN

2007 ◽  
Vol 17 (04) ◽  
pp. 1355-1366 ◽  
Author(s):  
WENWU YU ◽  
JINDE CAO
Keyword(s):  
Hopf Bifurcation ◽  
Time Delay ◽  
Frequency Domain ◽  
Harmonic Balance ◽  
Neuron System ◽  
Bifurcation Theorem ◽  
Nyquist Criterion ◽  
The Stability ◽  
Frequency Domain Approach ◽  
System With Time Delay

In this paper, a general two-neuron model with time delay is considered, where the time delay is regarded as a parameter. It is found that Hopf bifurcation occurs when this delay passes through a sequence of critical value. By analyzing the characteristic equation and using the frequency domain approach, the existence of Hopf bifurcation is determined. The stability of bifurcating periodic solutions are determined by the harmonic balance approach, Nyquist criterion and the graphic Hopf bifurcation theorem. Numerical results are given to justify the theoretical analysis.

scholarly journals Effects of Machine Tool Spindle Decay on the Stability Lobe Diagram: An Analytical-Experimental Study

2021 ◽  
Author(s):  
Omar Gaber ◽  
Seyed M. Hashemi
Keyword(s):  
Machine Tool ◽  
Natural Frequency ◽  
Dynamic Stiffness ◽  
Significant Shift ◽  
Stability Lobe Diagram ◽  
Element Analysis ◽  
Stability Lobe ◽  
Machine Tool Spindle ◽  
Linear Spring ◽  
The Stability

An analytical-experimental investigation of machine tool spindle decay and its effects of the system’s stability lobe diagram (SLD) is presented. A dynamic stiffness matrix (DSM)model for the vibration analysis of the OKADA VM500 machine spindle is developed and is validated against Finite Element Analysis (FEA).The model is then refined to incorporate flexibility of the system’s bearings, originally modeled as simply supported boundary conditions, where the bearings are modeled as linear spring elements.The system fundamental frequency obtained from the modal analysis carried on an experimental setup is then used to calibrate the DSM model by tuning the springs’ constants. The resulting natural frequency is also used to determine the 2D stability lobes diagram (SLD) for said spindle. Exploiting the presented approach and calibrated DSM model it is shown that a hypothetical 10% change in the natural frequency would result in a significant shift in the SLD of the spindle system, which should be taken into consideration to ensure chatter-free machining over the spindle’s life cycle.

Stability Prediction of Milling Process With Closed Machining System Dynamics With Flexible Thin-Walled Workpiece

2015 ◽  
Author(s):  
Chao Xu ◽  
Pingfa Feng ◽  
Dingwen Yu ◽  
Zhijun Wu ◽  
Jianfu Zhang
Keyword(s):  
Support System ◽  
Milling Process ◽  
Machining Process ◽  
Stability Lobe Diagram ◽  
Closed Model ◽  
Flexible Support ◽  
Stability Lobe ◽  
Machining System ◽  
Thin Walled ◽  
The Stability

Despite recent advances and improvements in modeling and prediction of the dynamics of the machining process, an efficient machining process is limited due to chatter and instability of machining system. In fact, the machining system contains various kinds of joints, which cause difficulties in dynamics modeling, simulation and prediction. Moreover, the flexible support system results in large deformation and violent vibration of the workpiece when machining, and the thin-walled workpiece easily gives rise to the chatter of the machining system. Therefore, the dynamics of the flexible support system was considered to calculate stability lobe diagram in the modeling of milling process. The whole machining system was regarded as a closed loop composed by the machine tool structures, support, workpiece and machining process. In this paper, the receptance coupling (RC) method was introduced to predict the dynamics of the closed machining system. A milling process was taken for example to predict the chatter limitations using the dynamics of closed model. The mathematical model of the machining system (machine tool structures, spindle, holder and tool), together with the details of joint contacts, was given based on the RC method. The RC model was used to obtain the dynamics of the system, while receptance of the tool point was coupled. Based on the coupling model of the machining system, the depth limitations under different speeds were estimated for the technology parameter optimization in milling process. The response was considered to be the sum of the cutting point and the support system. The flexibility of the support system was considered to be the feedback of the cutting stiffness. By this means, the traditional model was modified to calculate the stability lobe diagram based on the dynamics of the spindle and support system. Furthermore, the milling experiment was carried out to verify the prediction results, and the dominant natural frequencies of receptance at tool point were obtained by modal testing to define the stability lobe diagram. It was found that the chatter results matched well with the stability lobes. It was concluded that the support system with poor stiffness might cause violent chatter especially when the workpiece was thin-walled. The cutting depth limitations of the flexible support system were lower than that of the rigid one. Moreover, this closed model of the machining system is appropriate for the chatter prediction of the flexible support system or thin-walled workpiece, so it is helpful for a better parameter optimization.

scholarly journals Effects of Machine Tool Spindle Decay on the Stability Lobe Diagram: An Analytical-Experimental Study

2021 ◽  
Author(s):  
Omar Gaber ◽  
Seyed M. Hashemi
Keyword(s):  
Machine Tool ◽  
Natural Frequency ◽  
Dynamic Stiffness ◽  
Significant Shift ◽  
Stability Lobe Diagram ◽  
Element Analysis ◽  
Stability Lobe ◽  
Machine Tool Spindle ◽  
Linear Spring ◽  
The Stability

An analytical-experimental investigation of machine tool spindle decay and its effects of the system’s stability lobe diagram (SLD) is presented. A dynamic stiffness matrix (DSM)model for the vibration analysis of the OKADA VM500 machine spindle is developed and is validated against Finite Element Analysis (FEA).The model is then refined to incorporate flexibility of the system’s bearings, originally modeled as simply supported boundary conditions, where the bearings are modeled as linear spring elements.The system fundamental frequency obtained from the modal analysis carried on an experimental setup is then used to calibrate the DSM model by tuning the springs’ constants. The resulting natural frequency is also used to determine the 2D stability lobes diagram (SLD) for said spindle. Exploiting the presented approach and calibrated DSM model it is shown that a hypothetical 10% change in the natural frequency would result in a significant shift in the SLD of the spindle system, which should be taken into consideration to ensure chatter-free machining over the spindle’s life cycle.

scholarly journals Analysis of the Tool Stick-Out Influence on Machining Chatter

2021 ◽  
Author(s):  
Asier Barbeito Albizu ◽  
Pedro-José Arrazola ◽  
Klaus Bonde Ørskov
Keyword(s):  
Trial And Error ◽  
Machining Processes ◽  
Stability Lobe Diagram ◽  
Workpiece Surface ◽  
Stability Lobe ◽  
Excited Vibration ◽  
Machining Chatter ◽  
Trial And Error Method ◽  
The Stability ◽  
Error Method

Increased stability in machining processes is highly desired by all machining industries when vibrations and specially chatter occur. This phenomenon is defined as a self-excited vibration that occurs due to the regeneration of waviness of the workpiece surface. In machining industry, the trend is to rely on the trial and error method or mere experience when deciding the machining spindle speeds, depths of cut and tool stick-outs, all of which are parameters directly related to chatter occurrence. Currently, the shortest possible tool stick-out is chosen by default, but literature has proven that longer stick-outs may bring some advantages when it comes to material removal rates. Aiming to prove this theory, this paper will discuss the influence of the tool stick-out on machining chatter occurrence. To that end, the effect of the tool stick-out on the modal parameters of the system, on the Stability Lobe Diagram (SLD) and on productivity will be analysed. Therefore, a number of Tap-Tests to different tool/tool-holder/stick-out combinations have been performed, in order to gather the data (FRFs and SLDs) where the analysis is based on. Last but not least, some machining tests have been conducted aiming to compare the theoretical chatter occurrence conditions, provided by the SLD, with the experimental ones. For that, two Al5083 workpieces have been slot milled under different cutting conditions, facilitating the unexpected results wherein the conclusions have been based upon.

Double Loop Autopilot Design Based on Frequency Domain

2011 ◽  
Vol 301-303 ◽  
pp. 1724-1729
Author(s):  
Mei Sa Pang ◽  
Deng Hua Li ◽  
Jun Fang Fan ◽  
Xue Fei Li
Keyword(s):  
System Design ◽  
Frequency Domain ◽  
Static Stability ◽  
Double Loop ◽  
Guidance And Control ◽  
Control Gain ◽  
Aerodynamic Parameters ◽  
The Stability ◽  
And Control ◽  
Frequency Domain Approach

The static stability of missile pitching movement is one of the important performances in guidance and control systems. In this paper, a method which consists of the single and double loop longitudinal autopilot using frequency domain approach is proposed to solve the problem efficiently. Single-loop autopilot is used to simplify the system design when the missile is highly static stable; the double-loop autopilot is employed to stabilize the system and improve frequency performance when the missile is static stable or static unstable. Control gain of the system is determined by aerodynamic parameters and frequency domain indexes. The simulation result shows that double-loop autopilot based on frequency domain simplified the system design and improved the stability and robustness of missile system.

The Effect of Cutting Process Parameters on the Stability in Milling

2014 ◽  
Vol 887-888 ◽  
pp. 1200-1204 ◽  
Author(s):  
Te Ching Hsiao ◽  
Shyh Chour Huang
Keyword(s):  
Damping Ratio ◽  
Milling Process ◽  
Material Behavior ◽  
Cutting Process ◽  
Force Model ◽  
Stability Lobe Diagram ◽  
Workpiece Material ◽  
Stability Lobe ◽  
The Stability ◽  
Tool Diameter

In the milling process, the dynamic system in the cutting process is composed of the tool, workpiece, and machine tools themselves. Therefore the mill geometric parameter, workpiece material behavior, and the modal parameters of the cutting system all will influence the stability in milling. Using FLN method and convolution force model to predict the chatter stability of milling process, and discussing the effect of milling parameter on the stability in this article. According to the result: with the increase of the tool diameter, stiffness, damping ratio or the reducing of tangential cutting force coefficient and radial width of cut, the stability lobe diagram tends to move upward. With the increase of natural frequency, the stability lobe diagram tends to move to right side. With the increase of the number of tooth, the stability lobe diagram tends to move downward.

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