scholarly journals Disturbance of the Regenerative Effect by Use of Milling Tools Modified with Asymmetric Dynamic Properties

2020 ◽  
Vol 4 (3) ◽  
pp. 67
Author(s):  
Jonas Baumann ◽  
Andreas Wirtz ◽  
Tobias Siebrecht ◽  
Dirk Biermann
Keyword(s):  
Dynamic Properties ◽  
Constant Width ◽  
Chip Thickness ◽  
Stability Limit ◽  
Dynamic Compliance ◽  
Depth Of Cut ◽  
Regenerative Effect ◽  
The Stability ◽  
Tool Shank ◽  
Milling Tools

Milling processes are often limited by self-excited vibrations of the tool or workpiece, generated by the regenerative effect, especially when using long cantilevered tools or machining thin-walled workpieces. The regenerative effect arises from a periodic modulation of the uncut chip thickness within the frequencies of the eigenmodes, which results in a critical excitation in the consecutive cuts or tooth engagements. This paper presents a new approach for disturbing the regenerative effect by using milling tools which are modified with asymmetric dynamic properties. A four-fluted milling tool was modified with parallel slots in the tool shank in order to establish asymmetric dynamic characteristics or different eigenfrequencies for consecutive tooth engagements, respectively. Measurements of the frequency response functions at the tool tip showed a decrease in the eigenfrequencies as well as an increase in the dynamic compliance in the direction of the grooves. Milling experiments with a constant width of cut and constantly increasing axial depth of cut indicated a significant increase in the stability limit for the specific preparations of up to 69%.

scholarly journals Chatter identification in milling of Inconel 625 based on recurrence plot technique and Hilbert vibration decomposition

2018 ◽  
Vol 148 ◽  
pp. 09003 ◽  
Author(s):  
Paweł Lajmert ◽  
Rafał Rusinek ◽  
Bogdan Kruszyński
Keyword(s):  
Stability Limit ◽  
Recurrence Plot ◽  
Milling Process ◽  
Machining Process ◽  
Inconel 625 ◽  
Depth Of Cut ◽  
Force Measurements ◽  
Stability Lobe ◽  
Theoretical Finding ◽  
The Stability

In the paper a cutting stability in the milling process of nickel based alloy Inconel 625 is analysed. This problem is often considered theoretically, but the theoretical finding do not always agree with experimental results. For this reason, the paper presents different methods for instability identification during real machining process. A stability lobe diagram is created based on data obtained in impact test of an end mill. Next, the cutting tests were conducted in which the axial cutting depth of cut was gradually increased in order to find a stability limit. Finally, based on the cutting force measurements the stability estimation problem is investigated using the recurrence plot technique and Hilbert vibration decomposition method.

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.

Investigation of the Dynamics of Microend Milling—Part II: Model Validation and Interpretation

2006 ◽  
Vol 128 (4) ◽  
pp. 901-912 ◽  
Author(s):  
Martin B. G. Jun ◽  
Richard E. DeVor ◽  
Shiv G. Kapoor
Keyword(s):  
Dynamic Model ◽  
End Milling ◽  
Elastic Recovery ◽  
Chip Thickness ◽  
Thickness Effect ◽  
Depth Of Cut ◽  
Minimum Chip Thickness ◽  
Microend Milling ◽  
The Stability ◽  
Cutting Mechanisms

In Part II of this paper, experimental and analytical methods have been developed to estimate the values of the process faults defined in Part I of this paper. The additional faults introduced by the microend mill design are shown to have a significant influence on the total net runout of the microend mill. The dynamic model has been validated through microend milling experiments. Using the dynamic model, the effects of minimum chip thickness and elastic recovery on microend milling stability have been studied over a range of feed rates for which the cutting mechanisms vary from ploughing-dominated to shearing-dominated. The minimum chip thickness effect is found to cause feed rate dependent instability at low feed rates, and the range of unstable feed rates depends on the axial depth of cut. The effects of process faults on microend mill vibrations have also been studied and the influence of the unbalance from the faults is found to be significant as spindle speed is increased. The stability characteristics due to the regenerative effect have been studied. The results show that the stability lobes from the second mode of the microend mill, which are generally neglected in macroscale end milling, affect the microend mill stability significantly.

scholarly journals Estimates of the bistable region in metal cutting

2008 ◽  
Vol 464 (2100) ◽  
pp. 3255-3271 ◽  
Author(s):  
Zoltan Dombovari ◽  
R. Eddie Wilson ◽  
Gabor Stepan
Keyword(s):  
Cutting Force ◽  
Metal Cutting ◽  
Classical Model ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Stability Limit ◽  
Force Characteristic ◽  
Inflexion Point ◽  
The Stability ◽  
Force Characteristics

The classical model of regenerative vibration is investigated with new kinds of nonlinear cutting force characteristics. The standard nonlinear characteristics are subjected to a critical review from the nonlinear dynamics viewpoint based on the experimental results available in the literature. The proposed nonlinear model includes finite derivatives at zero chip thickness and has an essential inflexion point. In the case of the one degree-of-freedom model of orthogonal cutting, the existence of unstable self-excited vibrations is proven along the stability limits, which is strongly related to the force characteristic at its inflexion point. An analytical estimate is given for a certain area below the stability limit where stable stationary cutting and a chaotic attractor coexist. It is shown how this domain of bistability depends on the theoretical chip thickness. The comparison of these results with the experimental observations and also with the subcritical Hopf bifurcation results obtained for standard nonlinear cutting force characteristics provides relevant information on the nature of the cutting force nonlinearity.

Mode-Coupled Regenerative Machine Tool Vibrations

2003 ◽  
Author(s):  
Tama´s Kalma´r-Nagy ◽  
Francis C. Moon
Keyword(s):  
Machine Tool ◽  
Cutting Tool ◽  
Chip Thickness ◽  
The Other ◽  
Lumped Parameter Model ◽  
Regenerative Effect ◽  
Lumped Parameter ◽  
Tool Vibrations ◽  
The Stability ◽  
Effect Time

In this paper a new 3 degree-of-freedom lumped-parameter model for machine tool vibrations is developed and analyzed. One mode is shown to be stable and decoupled from the other two, and thus the stability of the system can be determined by analyzing the remaining two modes. It is shown that this mode-coupled nonconservative cutting tool model including the regenerative effect (time delay) can produce an instability criteria that admits low-level or zero chip thickness chatter.

scholarly journals INFLUENCE OF LINEAR FEED DRIVE CONTROLLER SETTING IN CNC TURNING LATHE ON THE STABILITY OF MACHINING

2019 ◽  
Vol 19 (2) ◽  
pp. 18-31 ◽  
Author(s):  
Jan GRAU ◽  
Matej SULITKA ◽  
Pavel SOUCEK
Keyword(s):  
Simulation Model ◽  
Dynamic Compliance ◽  
Ball Screw ◽  
Depth Of Cut ◽  
Cnc Turning ◽  
Feed Drive ◽  
Drive Control ◽  
The Stability ◽  
Ball Screw Drive ◽  
Stability Limits

The paper deals with the influence of linear feed drive controller setting of a CNC turning lathe on the stability of machining. A coupled simulation model of feed drive control and ball screw drive mechanics with a transmission belt was created and validated by the feed drive diagnostic measurements. The influence of drive control on the overall dynamic compliance at the TCP and the limits of stable depth of cut was examined. Impact of the feed drive actual kinematics configuration on the stability limits was studied as well.

A simulation apparatus for the experimental study of batch reactor control methods

1986 ◽  
Vol 51 (6) ◽  
pp. 1259-1267
Author(s):  
Josef Horák ◽  
Petr Beránek
Keyword(s):  
Experimental Study ◽  
Closed Loop ◽  
Dynamic Properties ◽  
Batch Reactor ◽  
Exothermic Reaction ◽  
Electric Heating ◽  
Batch Reactors ◽  
Exchange Area ◽  
The Stability ◽  
Methods Of Control

A simulation apparatus for the experimental study of the methods of control of batch reactors is devised. In this apparatus, the production of heat by an exothermic reaction is replaced by electric heating controlled by a computer in a closed loop; the reactor is cooled with an external cooler whose dynamic properties can be varied while keeping the heat exchange area constant. The effect of the cooler geometry on its dynamic properties is investigated and the effect of the cooler inertia on the stability and safety of the on-off temperature control in the unstable pseudostationary state is examined.

Effects of Insert Nose Radius and Processing Cutting Parameter on the Surface Roughness of Aisi 316 Stainless Steel

2010 ◽  
Vol 447-448 ◽  
pp. 51-54
Author(s):  
Mohd Fazuri Abdullah ◽  
Muhammad Ilman Hakimi Chua Abdullah ◽  
Abu Bakar Sulong ◽  
Jaharah A. Ghani
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Aisi 316

The effects of different cutting parameters, insert nose radius, cutting speed and feed rates on the surface quality of the stainless steel to be use in medical application. Stainless steel AISI 316 had been machined with three different nose radiuses (0.4 mm 0.8 mm, and 1.2mm), three different cutting speeds (100, 130, 170 m/min) and feed rates (0.1, 0.125, 0.16 mm/rev) while depth of cut keep constant at (0.4 mm). It is seen that the insert nose radius, feed rates, and cutting speed have different effect on the surface roughness. The minimum average surface roughness (0.225µm) has been measured using the nose radius insert (1.2 mm) at lowest feed rate (0.1 mm/rev). The highest surface roughness (1.838µm) has been measured with nose radius insert (0.4 mm) at highest feed rate (0.16 mm/rev). The analysis of ANOVA showed the cutting speed is not dominant in processing for the fine surface finish compared with feed rate and nose radius. Conclusion, surface roughness is decreasing with decreasing of the feed rate. High nose radius produce better surface finish than small nose radius because of the maximum uncut chip thickness decreases with increase of nose radius.

Modal Analyses of Deployable Truss Structures Based on Shape Memory Polymer Composites

2016 ◽  
Vol 08 (07) ◽  
pp. 1640009 ◽  
Author(s):  
Fengfeng Li ◽  
Liwu Liu ◽  
Xin Lan ◽  
Tong Wang ◽  
Xiangyu Li ◽  
...  
Keyword(s):  
Finite Element ◽  
Shape Memory ◽  
Polymer Composites ◽  
Dynamic Properties ◽  
Low Cost ◽  
Shape Memory Polymer ◽  
Truss Structures ◽  
Modal Test ◽  
The Stability ◽  
Mechanical Devices

With large spatial deployable antennas used more widely, the stability of deployable antennas is attracting more attention. The form of the support structure is an important factor of the antenna’s natural frequency, which is essential to study to prevent the resonance. The deployable truss structures based on shape memory polymer composites (SMPCs) have made themselves feasible for their unique properties such as highly reliable, low-cost, light weight, and self-deployment without complex mechanical devices compared with conventional deployable masts. This study offers deliverables as follows: an establishment of three-longeron beam and three-longeron truss finite element models by using ABAQUS; calculation of natural frequencies and vibration modes; parameter studies for influence on their dynamic properties; manufacture of a three-longeron truss based on SMPC, and modal test of the three-longeron truss. The results show that modal test and finite element simulation fit well.

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