Spindle Speed Variation for Regenerative Chatter Suppression in Turning Process With Tool Wear Effect

2010 ◽  
Author(s):  
Kambiz Haji Hajikolaei ◽  
Masoud Rahaeifard ◽  
Gholamreza Vossoughi ◽  
Mohammadreza Movahhedy
Keyword(s):  
Tool Wear ◽  
Removal Rate ◽  
Spindle Speed ◽  
Turning Process ◽  
Machining Processes ◽  
Chatter Suppression ◽  
Spindle Speed Variation ◽  
Set Up ◽  
The Stability ◽  
Delay Differential

Chatter suppression in machining processes results in more material removal rate, high precision and surface quality. In this paper, a single degree of freedom model of orthogonal turning process is used to set up the delay differential equation of motion with considering the tool wear effect as a contact force between the workpiece and tool flank surfaces. Sinusoidal spindle speed variations with different frequencies around the mean speed are modulated to disturb the regenerative mechanism. The optimal amplitudes of the speed modulations are found based on a genetic algorithm such that the input energy to the turning process is minimized. Results of the stability analysis and the controller effect for two distinct cases of one and three sinusoidal speed are presented and compared.

Adaptive Control of Regenerative Chatter in Turning Process With Tool Wear Effect

2009 ◽  
Author(s):  
Kambiz Haji Hajikolaei ◽  
Hamed Moradi ◽  
Aria Alasty ◽  
Gholam-Reza Vossoughi ◽  
Mohammad-Reza Movahhedi
Keyword(s):  
Adaptive Control ◽  
Tool Wear ◽  
Piezo Actuator ◽  
Control Input ◽  
Turning Process ◽  
Machining Processes ◽  
Chatter Suppression ◽  
Adaptive Control Strategy ◽  
Set Up ◽  
Delay Differential

Chatter suppression is of great importance for achieving high precision and surface quality in machining processes. A single degree of freedom model of orthogonal turning process is used to set up the nonlinear delay differential equation of motion. Tool wear effect is considered as the contact force between the workpiece and tool flank surfaces. Uncertainties in parameters of dynamic model and machining conditions are included in the model. An adaptive control strategy is applied for chatter suppression in cutting process. The force provided by a piezo-actuator is the control input of the system. Results of stability analysis and adaptive control for two distinct cases of sharp and worn tools are presented and compared.

Active Chatter Suppression in Turning by Simultaneous Adjustment of Amplitude and Frequency of Spindle Speed Variation

2019 ◽  
Vol 142 (2) ◽  
Author(s):  
Longyang Ding ◽  
Yuxin Sun ◽  
Zhenhua Xiong
Keyword(s):  
Removal Rate ◽  
Dimensional Accuracy ◽  
Spindle Speed ◽  
Machining Processes ◽  
Speed Variation ◽  
Chatter Suppression ◽  
Spindle Speed Variation ◽  
Simultaneous Adjustment ◽  
Adaptively Adjusting ◽  
Suppression Strategy

Abstract In machining processes, chatter suppression is very important for achieving a high material removal rate, good dimensional accuracy, and surface finish. With the merits of effectiveness and easy implementation, spindle speed variation (SSV) is regarded as a promising approach for chatter suppression. However, there is little research on the selection of SSV parameters for adaptive chatter suppression. Although the effectiveness of adaptively adjusting SSV amplitudes has been recently examined, the simultaneous adjustment of the SSV amplitude and frequency is expected to exhibit stronger adaptability since it achieves greater flexibility. In this paper, an active chatter suppression strategy is presented by simultaneously adjusting the amplitude and frequency of spindle speed variation. The effect of SSV parameters on stability improvement in turning processes including the tool wear is first investigated to demonstrate the necessity of simultaneously adjusting the amplitude and frequency for chatter suppression. Then, the proposed chatter suppression system is introduced, where two SSV parameters are simultaneously adjusted with optimal fractional-order proportional integral differential (FOPID) controllers to keep the chatter indicator close to a target value. Moreover, the FOPID controller is optimally tuned with the JADE algorithm. The effectiveness of the proposed method is verified by comparing simulated results of different SSV parameters adjusting strategies. Finally, machining tests are conducted to validate that the proposed chatter suppression method outperforms the existing SSV method in flexibility and effectiveness.

The Effect of Spindle Speed Variation on Chatter Suppression in Rotating-Tool Machining

2006 ◽  
Vol 505-507 ◽  
pp. 859-864 ◽  
Author(s):  
Chen Jung Li ◽  
A.G. Ulsoy ◽  
W.J. Endres
Keyword(s):  
Spindle Speed ◽  
System Stability ◽  
Constant Delay ◽  
Machining Processes ◽  
Speed Variation ◽  
Chatter Suppression ◽  
Spindle Speed Variation ◽  
Common Process ◽  
The Stability ◽  
Stability Limits

Spindle speed variation (SSV) is one of a number of promising strategies to suppress chatter. Most previous research on SSV stability analysis for nonintermittent machining processes has focused on stationary-bar boring or turning. However, nonintermittent rotating-tool machining is also a common process. This paper investigates the effect of SSV in nonintermittent rotating-tool machining, using rotating-bar boring as an example. This paper takes advantage of the rotating-frame approach and the resulting constant delay in the angle domain to investigate the SSV effect on system stability for rotating-bar boring. The results show that the SSV effect on rotating-bar boring flattens the stability lobes and lifts the tangential stability limits.

Machine-Tool Chatter Suppression by Multi-Level Random Spindle Speed Variation

1999 ◽  
Author(s):  
Alpay Yilmaz ◽  
Emad AL-Regib ◽  
Jun Ni
Keyword(s):  
Spindle Speed ◽  
New Method ◽  
Spindle System ◽  
Speed Variation ◽  
Chatter Suppression ◽  
Random Fashion ◽  
Spindle Speed Variation ◽  
Machine Tool Chatter ◽  
Multi Level ◽  
The Stability

Abstract This paper presents a new method for varying the spindle speed to suppress chatter in machining. The spindle speed is varied in pseudo-random fashion within the bandwidth of the spindle system. Both implementation issues and spindle system responses to such signals are investigated. A new method to analyze the stability of machining systems with varying spindle speed is also introduced. The effectiveness and advantages of the random spindle speed variation in chatter suppression is verified using numerical simulations and experiments.

Machine Tool Chatter Suppression by Multi-Level Random Spindle Speed Variation

2002 ◽  
Vol 124 (2) ◽  
pp. 208-216 ◽  
Author(s):  
Alpay Yilmaz ◽  
Emad AL-Regib ◽  
Jun Ni
Keyword(s):  
Spindle Speed ◽  
New Method ◽  
Spindle System ◽  
Speed Variation ◽  
Chatter Suppression ◽  
Random Fashion ◽  
Spindle Speed Variation ◽  
Machine Tool Chatter ◽  
Multi Level ◽  
The Stability

This paper presents a new method for varying the spindle speed to suppress chatter in machining. The spindle speed is varied in a pseudo-random fashion within the bandwidth of the spindle system. Both implementation issues and spindle system responses to such signals are investigated. A new method to analyze the stability of machining systems with varying spindle speed is also introduced. The effectiveness and advantages of the random spindle speed variation in chatter suppression is verified using numerical simulations and experiments.

scholarly journals Stability of Milling Process with Variable Spindle Speed Using Runge–Kutta-Based Complete Method

2021 ◽  
Vol 2021 ◽  
pp. 1-10
Author(s):  
Shujie Lv ◽  
Yang Zhao
Keyword(s):  
Removal Rate ◽  
Modulation Frequency ◽  
Milling Process ◽  
Spindle Speed ◽  
Calculation Time ◽  
Time Varying Delay ◽  
Speed Modulation ◽  
Runge Kutta ◽  
The Stability ◽  
Delay Differential

The variable-spindle-speed (VSS) technique is effective in preventing regenerative chatter in milling processes. However, spindle-speed-modulation parameters should be deliberately selected to augment the material removal rate. Stability-prediction algorithms of stability predicting play an important role in this respect, as they allow the prediction of stability for all ranges of a given spindle speed. The increase in calculation time in variable-spindle-speed milling, which is caused by the modulation frequency, hinders its practical use in the workshop. In this paper, a Runge–Kutta-based complete discretization method (RKCDM) is presented to predict the stability of milling with variable spindle speeds, which is described by a set of delay differential equations (DDEs) with time-periodic coefficients and time-varying delay. The convergence and calculation efficiency are compared with those of the semidiscretization method (SDM) under different testing configurations and milling conditions. Results show that RKCDM is more accurate and saves at least 50% of the calculation time of SDM. The effects of modulation parameters on the stability of VSS milling are explored through stability lobe diagrams produced from RKCDM.

Process Design and Optimization of end Milling Parameters of Al 7075 Metal Matrix Composite

2021 ◽  
pp. 929-937
Author(s):  
D. S. Sai Ravi Kiran ◽  
Alavilli Sai Apparao ◽  
Vempala GowriSankar ◽  
Shaik Faheem ◽  
Sheik Abdul Mateen ◽  
...  
Keyword(s):  
Tool Wear ◽  
Material Removal Rate ◽  
Metal Matrix ◽  
Material Removal ◽  
Hybrid Composites ◽  
End Milling ◽  
Removal Rate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Weight Percentage

This paper investigates the machinability characteristics of end milling operation to yield minimum tool wear with the maximum material removal rate using RSM. Twenty-seven experimental runs based on Box-Behnken Design of Response Surface Methodology (RSM) were performed by varying the parameters of spindle speed, feed and depth of cut in different weight percentage of reinforcements such as Silicon Carbide (SiC-5%, 10%,15%) and Alumina (Al2O3-5%) in alluminium 7075 metal matrix. Grey relational analysis was used to solve the multi-response optimization problem by changing the weightages for different responses as per the process requirements of quality or productivity. Optimal parameter settings obtained were verified through confirmatory experiments. Analysis of variance was performed to obtain the contribution of each parameter on the machinability characteristics. The result shows that spindle speed and weight percentage of SiC are the most significant factors which affect the machinability characteristics of hybrid composites. An appropriate selection of the input parameters such as spindle speed of 1000 rpm, feed of 0.02 mm/rev, depth of cut of 1 mm and 5% of SiC produce best tool wear outcome and a spindle speed of 1838 rpm, feed of 0.04 mm/rev, depth of cut of 1.81 mm and 6.81 % of SiC for material removal rate.

Investigations on the Application of Minimum Quantity Solid Lubrication in Turning

2017 ◽  
Author(s):  
Mayur A. Makhesana ◽  
Kaushik M. Patel
Keyword(s):  
Tool Wear ◽  
Cost Effective ◽  
Solid Lubricants ◽  
Cutting Fluid ◽  
Solid Lubrication ◽  
Machining Processes ◽  
Machined Surface ◽  
Minimum Quantity ◽  
Set Up ◽  
Experimental Findings

Machining is the manufacturing process, capable of producing required shape and size by material removal. In recent times industries are striving to enhance the performance of machining processes. One of the problem associated with machining is the amount of heat generation as a result of friction between tool and workpiece. Heat generated may affect the quality of machined surface and tool wear. In order to control it, cutting fluid is applied in large quantity. The problem arises with the use of cutting fluid is its effect on worker’s health and environment. The present investigation is an attempt to explore the use the solid lubricants in machining as an alternative to cutting fluid. The work involves development of minimum quantity solid lubrication set up. Turning experiments has been performed by applying solid lubricants mixed with cutting fluid in minimum quantity. The performance of minimum quantity solid lubrication has been assessed in form of obtained surface finish, power consumption and tool wear during turning. Experimental findings discovered the superiority of minimum quantity solid lubrication over conventional cutting fluid and can be considered as cost effective and sustainable lubrication method.

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