Stability-Based Spindle Design Optimization

2006 ◽  
Vol 129 (2) ◽  
pp. 407-415 ◽  
Author(s):  
Vincent Gagnol ◽  
Belhassen C. Bouzgarrou ◽  
Pascal Ray ◽  
Christian Barra
Keyword(s):  
High Speed ◽  
Modal Identification ◽  
Design Parameters ◽  
Depth Of Cut ◽  
Chatter Vibration ◽  
High Rotational Speed ◽  
Milling Operations ◽  
Critical Requirement ◽  
The Stability ◽  
Gyroscopic Coupling

Prediction of stable cutting regions is a critical requirement for high-speed milling operations. These predictions are generally made using frequency-response measurements of the tool-holder-spindle set obtained from a nonrotating spindle. However, significant changes in system dynamics occur during high-speed rotation. In this paper, a dynamic high-speed spindle-bearing system model is elaborated on the basis of rotor dynamics prediction and readjusted on the basis of experimental modal identification. The dependency of dynamic behavior on speed range is then investigated and determined with accuracy. Dedicated experiments are carried out in order to confirm model results. They show that dynamic effects due to high rotational speed and elastic deformations, such as gyroscopic coupling and spin softening, have a significant influence on spindle behavior. By integrating the modeled speed-dependent spindle transfer function in the chatter vibration stability approach of Altintas and Budak (1995, CIRPS Ann, 44(1), pp. 357–362), a new dynamic stability lobe diagram is predicted. Significant changes are observed in the stability limits constructed using the proposed approach and allow accurate prediction of cutting conditions to be established. Finally, optimization studies are performed on spindle design parameters in order to obtain a chatter vibration-free cutting operation at the desired speed and depth of cut for a given cutter.

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

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.

Stability of Milling Operations With Asymmetric Cutter Dynamics in Rotating Coordinates

2016 ◽  
Vol 138 (8) ◽  
Author(s):  
Alptunc Comak ◽  
Orkun Ozsahin ◽  
Yusuf Altintas
Keyword(s):  
Time Domain ◽  
Machine Tools ◽  
High Speed ◽  
End Mill ◽  
Spindle Shaft ◽  
Milling Operations ◽  
Stability Model ◽  
Principal Directions ◽  
The Stability ◽  
Rotating Coordinates

High-speed machine tools have parts with both stationary and rotating dynamics. While spindle housing, column, and table have stationary dynamics, rotating parts may have both symmetric (i.e., spindle shaft and tool holder) and asymmetric dynamics (i.e., two-fluted end mill) due to uneven geometry in two principal directions. This paper presents a stability model of dynamic milling operations with combined stationary and rotating dynamics. The stationary modes are superposed to two orthogonal directions in rotating frame by considering the time- and speed-dependent, periodic dynamic milling system. The stability of the system is solved in both frequency and semidiscrete time domain. It is shown that the stability pockets differ significantly when the rotating dynamics of the asymmetric tools are considered. The proposed stability model has been experimentally validated in high-speed milling of an aluminum alloy with a two-fluted, asymmetric helical end mill.

Investigation of Gyroscopic Effect on the Stability of High Speed Micromilling via Bifurcation Analysis

2021 ◽  
Vol 5 (4) ◽  
pp. 130
Author(s):  
Rinku K. Mittal ◽  
Ramesh K. Singh
Keyword(s):  
High Speed ◽  
Degrees Of Freedom ◽  
Multistep Method ◽  
Gyroscopic Effect ◽  
High Rotational Speed ◽  
Micro Tool ◽  
The Stability ◽  
Delay Differential ◽  
Stability Limits ◽  
Micro Tools

Catastrophic tool failure due to the low flexural stiffness of the micro-tool is a major concern for micromanufacturing industries. This issue can be addressed using high rotational speed, but the gyroscopic couple becomes prominent at high rotational speeds for micro-tools affecting the dynamic stability of the process. This study uses the multiple degrees of freedom (MDOF) model of the cutting tool to investigate the gyroscopic effect in machining. Hopf bifurcation theory is used to understand the long-term dynamic behavior of the system. A numerical scheme based on the linear multistep method is used to solve the time-periodic delay differential equations. The stability limits have been predicted as a function of the spindle speed. Higher tool deflections occur at higher spindle speeds. Stability lobe diagram shows the conservative limits at high rotational speeds for the MDOF model. The predicted stability limits show good agreement with the experimental limits, especially at high rotational speeds.

Criteria for the Stability Limit Prediction of High Speed Centrifugal Compressors With Vaneless Diffuser: Part I — Flow Structure Analysis

2020 ◽  
Author(s):  
Carlo Cravero ◽  
Davide Marsano
Keyword(s):  
Rotational Speed ◽  
High Speed ◽  
Stability Limit ◽  
Vaneless Diffuser ◽  
Centrifugal Compressors ◽  
Vaned Diffuser ◽  
High Rotational Speed ◽  
Lower Accuracy ◽  
The Stability ◽  
Computational Resources

Abstract High-speed centrifugal compressor requirements include a wide operating range between choking and stall especially for turbocharging applications. The prediction of the stability limit at different speeds is still challenging. In literature, several studies have been published on the phenomena that trigger the compressor instability. However, a comprehensive analysis of criteria that can be used in the first steps of centrifugal compressors design to predict the stability limit is still missing. In previous work the authors have already presented a criterion, so called “Stability Parameter”, to predict the surge line of centrifugal compressors based on a simplified CFD approach that does not require excessive computational resources and that can be efficiently used in the preliminary design phases. The above methodology has demonstrated its accuracy for centrifugal compressors with vaned diffuser, but a lower accuracy has been detected for vaneless diffusers. Before proceeding to identify additional criteria focused on compressors with vaneless diffuser, an in-depth fluid dynamics analysis has been necessary. This analysis has been also carried out through fully 3D unsteady simulations to allow identifying the real phenomena linked to the trigger of the instability of centrifugal compressors. It has been found how these phenomena are strongly related to the rotational speed, in particular have been shown the key role of the volute at high rotational speed.

Dynamics and Stability of Turn-Milling Operations With Varying Time Delay in Discrete Time Domain

2018 ◽  
Vol 140 (10) ◽  
Author(s):  
Alptunc Comak ◽  
Yusuf Altintas
Keyword(s):  
Time Domain ◽  
Chip Thickness ◽  
Body Motion ◽  
Depth Of Cut ◽  
Time Varying Delay ◽  
Milling Operations ◽  
Varying Time Delay ◽  
The Stability ◽  
Five Axis ◽  
Turn Milling

Turn-milling machines are widely used in industry because of their multifunctional capabilities in producing complex parts in one setup. Both milling cutter and workpiece rotate simultaneously while the machine travels in three Cartesian directions leading to five axis kinematics with complex chip generation mechanism. This paper presents a general mathematical model to predict the chip thickness, cutting force, and chatter stability of turn milling operations. The dynamic chip thickness is modeled by considering the rigid body motion, relative vibrations between the tool and workpiece, and cutter-workpiece engagement geometry. The dynamics of the process are governed by delayed differential equations by time periodic coefficients with a time varying delay contributed by two simultaneously rotating spindles and kinematics of the machine. The stability of the system has been solved in semidiscrete time domain as a function of depth of cut, feed, tool spindle speed, and workpiece speed. The stability model has been experimentally verified in turn milling of Aluminum alloy cut with a helical cylindrical end mill.

Stability Analysis of High-Speed Railway Vehicle Based on Multibody Dynamics Analysis

2013 ◽  
Vol 392 ◽  
pp. 156-160
Author(s):  
Ju Seok Kang
Keyword(s):  
Stability Analysis ◽  
Multibody Dynamics ◽  
High Speed ◽  
Equations Of Motion ◽  
Contact Forces ◽  
Design Parameters ◽  
Railway Vehicle ◽  
Dynamics Analysis ◽  
Contact Points ◽  
The Stability

Multibody dynamics analysis is advantageous in that it uses real dimensions and design parameters. In this study, the stability analysis of a railway vehicle based on multibody dynamics analysis is presented. The equations for the contact points and contact forces between the wheel and the rail are derived using a wheelset model. The dynamics equations of the wheelset are combined with the dynamics equations of the other parts of the railway vehicle, which are obtained by general multibody dynamics analysis. The equations of motion of the railway vehicle are linearized by using the perturbation method. The eigenvalues of these linear dynamics equations are calculated and the critical speed is found.

Avoiding Instability on the Milling of Parts with Thin Features

2006 ◽  
Vol 526 ◽  
pp. 37-42 ◽  
Author(s):  
Francisco Javier Campa ◽  
Luis Norberto López de Lacalle ◽  
S. Herranz ◽  
Aitzol Lamikiz ◽  
A. Rivero
Keyword(s):  
Dynamic Model ◽  
High Speed ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Test Device ◽  
High Speed Milling ◽  
Thin Walls ◽  
Chatter Vibrations ◽  
The Stability ◽  
Selection Of

In this paper, a 3D dynamic model for the prediction of the stability lobes of high speed milling is presented, considering the combined flexibility of both tool and workpiece. The main aim is to avoid chatter vibrations on the finish milling of aeronautical parts, which include thin walls and thin floors. In this way the use of complex fixtures is eliminated. Hence, an accurate selection of both axial depth of cut and spindle speed can be accomplished. The model has been validated by means of a test device that simulates the behaviour of a thin floor.

A Coupled Theoretical-Experimental Dynamical Model for Chatter Prediction in Milling Processes

2009 ◽  
Author(s):  
Giuseppe Catania ◽  
Nicolo` Mancinelli
Keyword(s):  
High Speed ◽  
Lumped Parameter Model ◽  
Milling Machine ◽  
Beam Shape ◽  
Milling Operations ◽  
Excited Vibration ◽  
Modal Model ◽  
Cutting Force Components ◽  
The Stability ◽  
Delay Differential

Productivity of high speed milling operations can be seriously limited by chatter occurrence. Several studies on this self-excited vibration can be found in the literature: simple models (1 or 2 dofs) are proposed, i.e. a lumped parameter model of the milling machine being excited by regenerative, time-varying cutting forces. In this study, a model of the milling machine is proposed: the machine frame and the spindle were modeled by an experimentally evaluated modal model, while the tool was modeled by a discrete modal approach, based on the continuous beam shape analytical eigenfunctions. The regenerative cutting force components lead to a set of Delay Differential Equations (DDEs) with periodic coefficients; DDEs were numerically integrated for different machining conditions. The stability lobe charts were evaluated using the semi-discretization method [6–7] that was extended to n dofs models (with n >2). Differences between the stability charts obtained by the low dofs models and the stability charts obtained by the new n dofs model are pointed out. Time histories and spectra related to the vibratory behavior of the system were numerically obtained to verify the effectiveness of the stability charts obtained with the n dofs modal model.

Chatter Vibration Modeling in High Speed Milling Operations

2008 ◽  
Author(s):  
Giuseppe Catania ◽  
Nicolo` Mancinelli
Keyword(s):  
High Speed ◽  
Removal Rate ◽  
Lumped Parameter Model ◽  
Beam Shape ◽  
Stability Lobe ◽  
Milling Operations ◽  
Excited Vibration ◽  
Cutting Force Components ◽  
The Stability ◽  
High Removal Rate

High removal rate in milling operations can be limited by chatter occurrence. Several studies on this self-excited vibration can be found in the literature: simple models (1 or 2 dofs) are proposed, i.e. a lumped parameter model of the milling machine being excited by regenerative, time-varying cutting forces. In this study, the machine tool spindle was modeled by a discrete modal approach, based on the continuous beam shape, analytical eigenfunctions, while the eigenvalues were mainly experimentally identified. The regenerative cutting force components lend to a set of Delay Differential Equations (DDEs) with periodic coefficients; DDEs were numerically integrated for different machining conditions. The stability lobe chart was evaluated using the semi-discretization method. Time histories, spectra and Poincare´ maps related to the vibratory behavior of the system were numerically obtained and differences with respect to the bifurcations predicted by the simplest models known in literature are pointed out. Some different behaviors in the shape of the stability lobe charts and in the spectra of the chatter vibrations were also observed.

Stability Prediction for Low Radial Immersion Milling

2002 ◽  
Vol 124 (2) ◽  
pp. 217-225 ◽  
Author(s):  
M. A. Davies ◽  
J. R. Pratt ◽  
B. Dutterer ◽  
T. J. Burns
Keyword(s):  
Stability Theory ◽  
High Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Peripheral Milling ◽  
Flexible Mode ◽  
Milling Operations ◽  
Radial Depth ◽  
Tool Diameter ◽  
Low Radial Immersion

Traditional regenerative stability theory predicts a set of optimally stable spindle speeds at integer fractions of the natural frequency of the most flexible mode of the system. The assumptions of this theory become invalid for highly interrupted machining, where the ratio of time spent cutting to not cutting (denoted ρ) is small. This paper proposes a new stability theory for interrupted machining that predicts a doubling in the number of optimally stable speeds as the value of ρ becomes small. The results of the theory are supported by numerical simulation and experiment. It is anticipated that the theory will be relevant for choosing optimal machining parameters in high-speed peripheral milling operations where the radial depth of cut is only a small fraction of the tool diameter.

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