A Study of Linear Joint and Tool Models in Spindle-Holder-Tool Receptance Coupling

2005 ◽  
Author(s):  
Timothy J. Burns ◽  
Tony L. Schmitz
Keyword(s):  
Frequency Response ◽  
High Speed ◽  
Nonlinear Least Squares ◽  
Analytical Models ◽  
Connection Matrix ◽  
Depth Of Cut ◽  
Combined System ◽  
Receptance Coupling ◽  
Overhang Length ◽  
Exponential Trend

The dynamics of a spindle-holder-tool (SHT) system during high-speed machining is sensitive to changes in tool overhang length. A well-known method for predicting the limiting depth of cut for avoidance of tool chatter requires a good estimate of the tool-point frequency response (FRF) of the combined system, which depends upon the tool length. In earlier work, a combined analytical and experimental method has been discussed, that uses receptance coupling substructure analysis (RCSA) for the rapid prediction of the combined spindle-holder-tool FRF. The basic idea of the method is to combine the measured direct displacement vs. force receptance (i.e., frequency response) at the free end of the spindle-holder (SH) system with calculated expressions for the tool receptances based on analytical models. The tool was modeled as an Euler-Bernoulli (EB) beam, the other three spindle-holder receptances were set equal to zero, and the model for the connection with the tool led to a diagonal matrix. The main conclusion of the earlier work was that there was an exponential trend in the dominant connection parameter, which enabled interpolation between tip receptance data for the longest and shortest tools in the combined SHT system. Thus, a considerable savings in time and effort could be realized for the particular SHT system. A question left open in the earlier work was: how general is this observed exponential trend? Here, to explore this question further, an analytical EB model is used for the SH system, so that all four of its end receptances are available, and the tool is again modeled as a free-free EB beam that is connected to the SH by a specified connection matrix, that includes nonzero off-diagonal terms. This serves as the “exact” solution. The approximate solution is once again formed by setting all but one SH receptance equal to zero, and the connection parameters are determined using nonlinear least squares software. Both diagonal and full connection matrices are investigated. The main result is that, for this system, in the case of a diagonal connecting matrix, there is no apparent trend in the dominant connecting spring stiffness with tool overhang length. However, in the full connecting matrix case, a general constant trend is observed, with some interesting exceptions.

scholarly journals Prediction of the Frequency Response Function of a Tool Holder-Tool Assembly Based on Receptance Coupling Method

2018 ◽  
Vol 8 (6) ◽  
pp. 3556-3560
Author(s):  
X. J. Xuan ◽  
Z. H. Haung ◽  
K. D. Wu ◽  
J. P. Hung
Keyword(s):  
Frequency Response ◽  
Response Function ◽  
Frequency Response Function ◽  
High Speed ◽  
Milling Process ◽  
Element Analysis ◽  
Tool Holder ◽  
Machine Performance ◽  
Receptance Coupling ◽  
Overhang Length

Regenerative chatter has a fatal influence on machine performance in high-speed milling process. Basically, machine condition without chattering can be selected from the stability lobes diagram, which is estimated from the tool point frequency response function (FRF). However, measurements of the tool point FRF would be a complicated and time-consuming task with less efficiency. Therefore prediction of the tool point FRF is of importance for further calculation of the machining stability. This study employed the receptance coupling analysis method to predict the FRF of a tool holder-tool module, which is normally composed of substructures, tool holder and cutter with different length. In this study, the angular components of FRFs of the substructures required for coupling operation were predicted by finite element analysis, apart from the translational components measured by vibration experiments. Using this method, the effects of the overhang length of the cutter on the dynamic characteristics have been proven and successfully verified by the experimental measurements. The proposed method can be an effective way to accurately predict the dynamic behavior of the spindle tool system with different tool holder-tool modules.

Tool Point Frequency Response Prediction for High-Speed Machining by RCSA

2001 ◽  
Vol 123 (4) ◽  
pp. 700-707 ◽  
Author(s):  
Tony L. Schmitz ◽  
Matthew A. Davies ◽  
Michael D. Kennedy
Keyword(s):  
Frequency Response ◽  
High Speed ◽  
Response Prediction ◽  
High Speed Machining ◽  
Receptance Coupling ◽  
Substructure Analysis ◽  
Receptance Coupling Substructure Analysis ◽  
Shrink Fit ◽  
Chatter Stability Prediction ◽  
Analytic Prediction

The implementation of high-speed machining for the manufacture of discrete parts requires accurate knowledge of the system dynamics. We describe the application of receptance coupling substructure analysis (RCSA) to the analytic prediction of the tool point dynamic response by combining frequency response measurements of individual components through appropriate connections. Experimental verification of the receptance coupling method for various tool geometries (e.g., diameter and length) and holders (HSK 63A collet and shrink fit) is given. Several experimental results are presented to demonstrate the practical applicability of the proposed method for chatter stability prediction in milling.

Receptance Coupling Study of Tool-Length Dependent Dynamic Absorber Effect

2004 ◽  
Author(s):  
Timothy J. Burns ◽  
Tony L. Schmitz
Keyword(s):  
Frequency Response ◽  
High Speed ◽  
Removal Rate ◽  
Stability Lobe ◽  
Receptance Coupling ◽  
Rapid Prediction ◽  
Substructure Analysis ◽  
Dynamic Absorber ◽  
Receptance Coupling Substructure Analysis ◽  
Free Material

The chatter-free material removal rate during high-speed machining of aluminum using long, slender endmills is limited by the cutting system dynamics, which changes with the tool length. Traditional stability-lobe diagrams that predict the maximum allowable chip width for a given spindle speed are determined using the tool point frequency response function. A brief review is given of a combined analytical and experimental method that uses receptance coupling substructure analysis (RCSA) for the rapid prediction of the tool-point frequency response as the tool length is varied. The basic idea of the method is to combine the measured direct displacement vs. force receptance (i.e., frequency response) at the free end of the spindle-holder system with analytical expressions for the tool receptances. The method is then used to provide an explanation for the dynamic absorber effect that has been observed in the context of tool-length tuning.

Frequency Response Studies using Receptance Coupling Approach in High Speed Spindles

2018 ◽  
Vol 100 (2) ◽  
pp. 311-322
Author(s):  
Jakeer Hussain Shaik ◽  
K. Ramakotaiah ◽  
J. Srinivas
Keyword(s):  
Frequency Response ◽  
High Speed ◽  
Receptance Coupling ◽  
Coupling Approach

scholarly journals Optimization and Tuning of Passive Tuned Mass Damper Embedded in Milling Tool for Chatter Mitigation

2020 ◽  
Vol 5 (1) ◽  
pp. 2
Author(s):  
Wenshuo Ma ◽  
Jingjun Yu ◽  
Yiqing Yang ◽  
Yunfei Wang
Keyword(s):  
Tuned Mass Damper ◽  
Structural Features ◽  
Milling Process ◽  
Diameter Ratio ◽  
Depth Of Cut ◽  
Receptance Coupling ◽  
Milling Tool ◽  
Mass Damper ◽  
Large Length ◽  
Deep Depth

Milling tools with a large length–diameter ratio are widely applied in machining structural features with deep depth. However, their high dynamic flexibility gives rise to chatter vibrations, which results in poor surface finish, reduced productivity, and even tool damage. With a passive tuned mass damper (TMD) embedded inside the arbor, a large length–diameter ratio milling tool with chatter-resistance ability was developed. By modeling the milling tool as a continuous beam, the tool-tip frequency response function (FRF) of the milling tool with TMD was derived using receptance coupling substructure analysis (RCSA), and the gyroscopic effect of the rotating tool was incorporated. The TMD parameters were optimized numerically with the consideration of mounting position based on the maximum cutting stability criterion, followed by the simulation of the effectiveness of the optimized and detuned TMD. With the tool-tip FRF obtained, the chatter stability of the milling process was predicted. Tap tests showed that the TMD was able to increase the minimum real part of the FRF by 79.3%. The stability lobe diagram (SLD) was predicted, and the minimum critical depth of cut in milling operations was enhanced from 0.10 to 0.46 mm.

Study on Edge Contact Area and Surface Integrity of Workpiece in Point Grinding Process

2009 ◽  
Vol 407-408 ◽  
pp. 577-581
Author(s):  
Shi Chao Xiu ◽  
Zhi Jie Geng ◽  
Guang Qi Cai
Keyword(s):  
Surface Integrity ◽  
Contact Area ◽  
High Speed ◽  
Ground Surface ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Edge Contact ◽  
Cylindrical Grinding ◽  
Theoretic Foundations

During cylindrical grinding process, the geometric configuration and size of the edge contact area between the grinding wheel and workpiece have the heavy effects on the workpiece surface integrity. In consideration of the differences between the point grinding and the conventional high speed cylindrical grinding, the geometric and mathematic models of the edge contact area in point grinding were established. Based on the models, the numerical simulation for the edge contact area was performed. By means of the point grinding experiment, the effect mechanism of the edge contact area on the ground surface integrity was investigated. These will offer the applied theoretic foundations for optimizing the point grinding angles, depth of cut, wheel and workpiece speed, geometrical configuration and size of CBN wheel and some other grinding parameters in point grinding process.

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

A Comprehensive Study on Surface Roughness in Machining of AISI D2 Hardened Steel

2012 ◽  
Vol 576 ◽  
pp. 60-63 ◽  
Author(s):  
N.A.H. Jasni ◽  
Mohd Amri Lajis
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Radial Depth ◽  
Aisi D2 ◽  
Coated Carbide

Hard milling of hardened steel has wide application in mould and die industries. However, milling induced surface finish has received little attention. An experimental investigation is conducted to comprehensively characterize the surface roughness of AISI D2 hardened steel (58-62 HRC) in end milling operation using TiAlN/AlCrN multilayer coated carbide. Surface roughness (Ra) was examined at different cutting speed (v) and radial depth of cut (dr) while the measurement was taken in feed speed, Vf and cutting speed, Vc directions. The experimental results show that the milled surface is anisotropic in nature. Surface roughness values in feed speed direction do not appear to correspond to any definite pattern in relation to cutting speed, while it increases with radial depth-of-cut within the range 0.13-0.24 µm. In cutting speed direction, surface roughness value decreases in the high speed range, while it increases in the high radial depth of cut. Radial depth of cut is the most influencing parameter in surface roughness followed by cutting speed.

Effect of Machining Parameters and Wear Mechanism in Milling Mold Steel AISI-P20 and AISI-1050

2014 ◽  
Vol 590 ◽  
pp. 294-298
Author(s):  
Pichai Janmanee ◽  
Somchai Wonthaisong ◽  
Dollathum Araganont
Keyword(s):  
Wear Mechanism ◽  
Feed Rate ◽  
High Speed ◽  
Removal Rate ◽  
Milling Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Aisi P20 ◽  
Steel Aisi ◽  
Quality Surface

In this study, effect of machining parameters and wear mechanism in milling process of mold steel AISI-P20 and AISI-1050, using 10 mm twin flute type end mill diameter. The experimental results found that characteristics of milling surfaces and wear of the mill end were directly influenced by changes of parameters for all test conditions. As a result, the quality of milling surfaces also changed. However, mould steels which had the good quality surface is AISI-1050, with roughnesses of 2.120 μm. Quality milling surfaces were milled by using the most suitable parameter feed rate of 45 mm/min, a spindle speed of 637 rpm and a cut depth level of 3 mm, for both grades. Moreover, material removal rate and duration of the milling process, the milling end mills affect wear of the edge in every bite when the feed rate is low, high speed and level depth of cut at least. It was found that limited wear less will affect the surface roughness (Ra) represents the good quality surface.

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