Adaptive Active Chatter Control in Milling Processes

2013 ◽  
Vol 136 (2) ◽  
Author(s):  
Zhiyong Chen ◽  
Hai-Tao Zhang ◽  
Xiaoming Zhang ◽  
Han Ding
Keyword(s):  
Performance Improvement ◽  
Adaptive Algorithm ◽  
Passive Control ◽  
Dynamic Phenomenon ◽  
Location Error ◽  
Machining Processes ◽  
Surface Location Error ◽  
Chatter Control ◽  
Surface Location ◽  
Fourier Series Analysis

Chatter is an undesirable dynamic phenomenon in machining processes, which causes cutting disturbance, overcut, quick tool wear, etc., and thus seriously impairs workpiece quality. To mitigate chatter, traditional methods called passive control focus on optimizing working spindle speeds and depths of cut. But they have inherent disadvantages in gaining highly efficient machining. On the contrary, the research in this paper is along the line of active control. Specifically, an adaptive algorithm is developed based on Fourier series analysis to deal with the so-called regenerative cutting force which causes chatter. As a result, chatter is remarkably mitigated. The performance improvement is illustrated by numerical simulation in terms of both stability lobes diagram (SLD) and surface location error (SLE).

Surface Location Error in Milling

2009 ◽  
pp. 173-198
Author(s):  
Tony L. Schmitz ◽  
Kevin S. Smith
Keyword(s):  
Location Error ◽  
Surface Location Error ◽  
Surface Location

Prediction of cumulative surface location error at the contact zone of in-process workpiece and milling tool

2020 ◽  
Vol 177 ◽  
pp. 105543 ◽  
Author(s):  
Dongqian Wang ◽  
Michael Löser ◽  
Yunhu Luo ◽  
Steffen Ihlenfeldt ◽  
Xibin Wang ◽  
...  
Keyword(s):  
Contact Zone ◽  
Location Error ◽  
Surface Location Error ◽  
Milling Tool ◽  
Surface Location

Assessment of Friction Behavior with Surface Location Error Analysis in Milling Process

2019 ◽  
Vol 823 ◽  
pp. 129-134
Author(s):  
N.A. Rafan ◽  
Siti Nur Madihah Ab Rashid ◽  
Z. Jamaludin
Keyword(s):  
Manufacturing Industry ◽  
Milling Process ◽  
Work Piece ◽  
Location Error ◽  
Friction Behavior ◽  
Error Location ◽  
Surface Location Error ◽  
Highly Nonlinear ◽  
Important Quality ◽  
Surface Location

Accurate roundness or circularity measurement is essential to obtain correct functioning of assemblies, making roundness an important quality control parameter in manufacturing industry. Since circular motion while milling a circular work piece leads to quadrant glitches, a phenomenon familiar with existence of highly nonlinear friction behavior, roundness measurement was conducted to investigate this surface location error due to feed rate of the moving work table. This paper presents friction behavior on a milling process circular work piece in line resulted from identified surface error location (SLE).

Chatter stability and surface location error predictions in milling with mode coupling and process damping

2017 ◽  
Vol 233 (3) ◽  
pp. 686-698 ◽  
Author(s):  
Zhongyun Li ◽  
Shanglei Jiang ◽  
Yuwen Sun
Keyword(s):  
Dynamic Model ◽  
Mode Coupling ◽  
Vital Role ◽  
Milling Process ◽  
Location Error ◽  
Process Damping ◽  
Stability Lobes ◽  
Surface Location Error ◽  
Surface Location ◽  
Extended Dynamic

Together with machining chatter, surface location error induced by forced vibration may also inhibit productivity and affect workpiece surface quality in milling process. Addressing these issues needs the combined consideration of stability lobes diagram and surface location error predictions. However, mode coupling and process damping are seldom taken into consideration. In this article, an extended dynamic milling model including mode coupling and process damping is first built based on classical 2-degree-of-freedom dynamic model with regeneration. Then, a second-order semi-discretization method is proposed to simultaneously predict the stability lobes diagram and surface location error by solving this extended dynamic model. The rate of convergence of the proposed method is also investigated. Finally, a series of experiments are conducted to verify the veracity of the extended dynamic model. The modal parameters including direct and cross terms are identified by impact experiments. Via experimental verification, the experimental results show a good correlation with the predicted stability lobes diagram and surface location error based on the extended dynamic model. Also, the effects of mode coupling and process damping are revealed. Mode coupling increases the whole stability region; however, process damping plays a vital role in stability improvement mainly at low spindle speeds.

A Numerical Study of Uncertainty in Stability and Surface Location Error in High-Speed Milling

2005 ◽  
Author(s):  
Mohammad H. Kurdi ◽  
Tony L. Schmitz ◽  
Raphael T. Haftka ◽  
Brian P. Mann
Keyword(s):  
High Speed ◽  
Numerical Study ◽  
Removal Rate ◽  
Operating Conditions ◽  
Location Error ◽  
High Speed Milling ◽  
Surface Location Error ◽  
Input Parameters ◽  
Surface Location ◽  
Axial Depth

High-speed milling offers an efficient tool for developing cost effective manufacturing processes with acceptable dimensional accuracy. Realization of these benefits depends on an appropriate selection of preferred operating conditions. In a previous study, optimization was used to find these conditions for two objectives: material removal rate (MRR) and surface location error (SLE), with a Pareto front or tradeoff curve found for the two competing objectives. However, confidence in the optimization results depends on the uncertainty in the input parameters to the milling model (time finite element analysis was applied here for simultaneous prediction of stability and surface location error). In this paper the uncertainty of these input parameters such as cutting force coefficients, tool modal parameters, and cutting parameters is evaluated. The sensitivity of the maximum stable axial depth, blim, to each input parameter at each spindle speed is determined. This enables identification of parameters with high contribution to stability lobe uncertainty. Two methods are used to calculate uncertainty: 1) Monte Carlo simulation; and 2) numerical derivatives of the system eigenvalues. Once the uncertainty in axial depth is calculated, its effect is observed in the MRR and SLE uncertainties. This allows robust optimization that takes into consideration both performance and uncertainty.

Simultaneous Optimization of Removal Rate and Part Accuracy in High-Speed Milling

2004 ◽  
Author(s):  
Mohammad H. Kurdi ◽  
Tony L. Schmitz ◽  
Raphael T. Haftka ◽  
Brian P. Mann
Keyword(s):  
Optimization Algorithm ◽  
High Speed ◽  
Removal Rate ◽  
Spindle Speed ◽  
Successful Implementation ◽  
Location Error ◽  
High Speed Milling ◽  
Surface Location Error ◽  
Surface Location ◽  
Selection Of

High-speed milling provides an efficient method for accurate discrete part fabrication. However, successful implementation requires the selection of appropriate operating parameters. Balancing the multiple process requirements, including high material removal rate, maximum part accuracy, sufficient tool life, chatter avoidance, and adequate surface finish, to arrive at an optimum solution is difficult without the aid of an optimization framework. In this paper an initial effort is made to apply analytical tools to the selection of optimum cutting parameters (spindle speed and depth of cut are considered at this stage). Two objectives are addressed simultaneously, maximum removal rate and minimum surface location error. The Time Finite Element Analysis method is used in the optimization algorithm. Sensitivity of the surface location error to small changes in spindle speed near tooth passing frequencies that are integer fractions of the system’s natural frequency corresponding to the most flexible mode is calculated. Results of the optimization algorithm are verified by experiment.

Harmonic Differential Quadrature Method for Surface Location Error Prediction and Machining Parameter Optimization in Milling

2015 ◽  
Vol 137 (2) ◽  
Author(s):  
Ye Ding ◽  
XiaoJian Zhang ◽  
Han Ding
Keyword(s):  
Differential Quadrature Method ◽  
Differential Quadrature ◽  
Machining Parameters ◽  
Quadrature Method ◽  
Location Error ◽  
Sampling Grid ◽  
Surface Location Error ◽  
Harmonic Differential Quadrature Method ◽  
Surface Location ◽  
Grid Points

This paper presents a semi-analytical numerical method for surface location error (SLE) prediction in milling processes, governed by a time-periodic delay-differential equation (DDE) in state-space form. The time period is discretized as a set of sampling grid points. By using the harmonic differential quadrature method (DQM), the first-order derivative in the DDE is approximated by the linear sums of the state values at all the sampling grid points. On this basis, the DDE is discretized as a set of algebraic equations. A dynamic map can then be constructed to simultaneously determine the stability and the steady-state SLE of the milling process. To obtain optimal machining parameters, an optimization model based on the milling dynamics is formulated and an interior point penalty function method is employed to solve the problem. Experimentally validated examples are utilized to verify the accuracy and efficiency of the proposed approach.

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