Mode Coupling Behavior in End Milling

2009 ◽  
Author(s):  
C. Y. Huang ◽  
J.-J. Junz Wang
Keyword(s):  
Mode Coupling ◽  
End Milling ◽  
Milling Process ◽  
Chatter Vibration ◽  
Rotation Direction ◽  
Coupling Behavior ◽  
Structure Vibration ◽  
The Stability ◽  
Milling Dynamics ◽  
End Milling Process

Chatter is caused by two main mechanisms: the regenerative waviness and the mode coupling. Both of these two chatter mechanisms always exist simultaneously, but most studies only discuss the regenerative chatter behavior. The purpose of this paper is to investigate the mode coupling behavior in end milling process. A mechanical model considering both of the regenerative and mode coupling effects is then constructed to simulate the milling dynamics. It is shown that the stability of milling is dominated by the eigenvalues of the process matrix and the structure vibration trajectories are affected by the eigenvectors of the process matrix. The rotation direction of chatter vibration is an important feature to determine whether mode coupling chatter occurs or not. By analyzing vibration trajectories, this paper then shows that chatter vibration will rotate in the direction which periodically accumulates the vibration energy. Finally, some methods for adjusting the cutting conditions to avoid the mode coupling chatter are proposed.

Investigation of Chatter Vibration in End-Milling Process by Considering Coupled System Model

2014 ◽  
Vol 939 ◽  
pp. 201-208
Author(s):  
Kosuke Hattori ◽  
Hiroyuki Kodama ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama
Keyword(s):  
Cutting Tool ◽  
End Milling ◽  
Milling Process ◽  
Work Piece ◽  
Vibration Modes ◽  
Test Results ◽  
Chatter Vibration ◽  
Simple Method ◽  
Excited Vibration ◽  
End Milling Process

Chatter vibration in cutting processes usually leads to surface finish degradation, tool damage, cutting noise, energy loss, etc. Self-excited vibration particularly seems to be a problem that is easily increased to large vibration. The regenerative effect is considered as one of the causes of chatter vibration. Although the chatter vibration occurs in various types of processing, the end-milling is a typical process that seems to cause the chatter vibration due to a lack of rigidity of one or more parts of the machine tools, cutting tool, and work-piece. The aim of our research is to propose a simple method to control chatter vibration of the end-milling process on the basis of a coupling model integrating the related various elements. In this study, hammering tests were carried out to measure the transfer function of a machine tool and cutting tool system, which seems to cause vibration. By comparing these results, finite elemental method (FEM) analysis models were constructed. Additionally, cutting experiments were carried out to confirm the chatter vibration frequencies in end-milling with a machining center. In the hammering tests, impulse hammer and multiple acceleration pick-ups are connected to a multi-channel FFT analyzer and estimate the natural frequencies and natural vibration modes. A simplified FEM model is proposed by circular section stepped beam elements on the basis of the hammering test results, considering a coupling effect. In comparisons of the calculated results and hammering test results, the vibration modes are in good agreement. As a result, the proposed model accurately predicts the chatter vibration considering several effects among the relating elements in end-milling. Moreover, it can be seen that the chatter vibration is investigated from a viewpoint of the integrating model of the end-milling process.

Dynamics and Stability of Five-Axis Ball-End Milling

2010 ◽  
Vol 132 (2) ◽  
Author(s):  
Erdem Ozturk ◽  
Erhan Budak
Keyword(s):  
Time Domain ◽  
End Milling ◽  
Milling Process ◽  
Ball End Milling ◽  
Part Quality ◽  
Stability Diagrams ◽  
Milling Operations ◽  
The Stability ◽  
Milling Dynamics ◽  
Five Axis

Being one of the most important problems in machining, chatter vibrations must be avoided as they result in high cutting forces, poor surface finish, and unacceptable part quality. Using stability diagrams is an effective method to predict chatter free cutting conditions. Although there have been numerous works in milling dynamics, the stability of five-axis ball-end milling has not been studied in detail. In this paper, the stability of the five-axis ball-end milling is analyzed using analytical (frequency domain), numerical (time-domain), and experimental methods. The models presented consider 3D dynamics of the five-axis ball-end milling process including the effects of all important process parameters such as the lead and tilt angles. Both single- and multi-frequency solutions are presented. Unlike other standard milling cases, it is observed that adding multi-frequency effects in the solution has marginal influence on the stability diagrams for five-axis ball-end milling operations due to effects of the ball-end milling geometry on the engagement region, thus, on the directional coefficients. The stability limits predicted by single- and multi-frequency methods are compared with time-domain simulations and experiments. Using the models and experimental results, the effects of the lead and tilt angles on the stability diagrams are also shown. The presented models can be used in analysis of five-axis ball-end milling dynamics as well as in the selection of the milling conditions for increased stability.

Analysis and Research of the Vibration of the High-Speed Cutting Process

2011 ◽  
Vol 188 ◽  
pp. 642-647
Author(s):  
A.M. Tang ◽  
Z.X. Zhou ◽  
W.W. Huang
Keyword(s):  
Analytical Model ◽  
High Speed ◽  
End Milling ◽  
Milling Process ◽  
Cutting Process ◽  
Stable Region ◽  
High Speed Cutting ◽  
Dynamic Cutting Force ◽  
The Stability ◽  
End Milling Process

The paper takes the dynamic cutting process as research subject to analyze and research the high-speed milling process. Through carrying out the dynamical modeling and simulation of the milling process, the analytical model of the dynamic cutting force and the chatter stable region of the spiral end mill were established. On the basis of the analytical model, the simulation of the end milling process was carried out, and the interpretational domain of the simulation was confirmed experimentally. Finally, the parameter optimization of the high-speed cutting process was investigated in the term of the stability of the cutting process.

TOPSIS based selection of optimal end milling process parameters

2020 ◽  
Author(s):  
A. Singh ◽  
I. Shivakoti ◽  
Z. Mustafa ◽  
R. Phipon ◽  
A. Sharma
Keyword(s):  
Process Parameters ◽  
End Milling ◽  
Milling Process ◽  
End Milling Process ◽  
Selection Of

Machining feasibility and sustainability study on end milling process of Monel alloy

2021 ◽  
Author(s):  
Muhammed Shihan ◽  
J. Chandradass ◽  
T.T.M. Kannan ◽  
S.M. Sivagami
Keyword(s):  
End Milling ◽  
Milling Process ◽  
End Milling Process
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