Prediction and Avoidance of Chatter in Milling of Thin-Walled Structure

2009 ◽  
Vol 407-408 ◽  
pp. 404-407 ◽  
Author(s):  
Hiroyuki Sasahara ◽  
Yoshihisa Naito

An objective of this study is to develop a new method for the prediction and the avoidance of chatter vibration in milling operation of thin-walled structure by using 3D-CAD and CAE approach. Also, a new identification method for the modal parameters of a vibration system by analyzing radiated sound pressure from vibrated workpiece accelerated by an impulse force is proposed. Then chatter stability lobes are predicted using those modal parameters. Stiffness and modal shapes of the workpiece were obtained using commercial finite element method (FEM) code, and the model was made by 3D-CAD. The damping ratio, which cannot be determined through FEM analysis, was identified from the relationship between the sound pressure radiated from the workpiece and the impulse force. Chatter stability limit was analyzed with the modal parameters obtained through these procedures, and compared with the cutting experiment on the chatter stability limit. The experimental and predicted stability limits are in good agreement. The proposed procedure will help to set the cutting conditions to avoid the chatter.

2020 ◽  
Vol 14 (3) ◽  
pp. 327-354
Author(s):  
Mohammad Omidalizarandi ◽  
Ralf Herrmann ◽  
Boris Kargoll ◽  
Steffen Marx ◽  
Jens-André Paffenholz ◽  
...  

AbstractToday, short- and long-term structural health monitoring (SHM) of bridge infrastructures and their safe, reliable and cost-effective maintenance has received considerable attention. From a surveying or civil engineer’s point of view, vibration-based SHM can be conducted by inspecting the changes in the global dynamic behaviour of a structure, such as natural frequencies (i. e. eigenfrequencies), mode shapes (i. e. eigenforms) and modal damping, which are known as modal parameters. This research work aims to propose a robust and automatic vibration analysis procedure that is so-called robust time domain modal parameter identification (RT-MPI) technique. It is novel in the sense of automatic and reliable identification of initial eigenfrequencies even closely spaced ones as well as robustly and accurately estimating the modal parameters of a bridge structure using low numbers of cost-effective micro-electro-mechanical systems (MEMS) accelerometers. To estimate amplitude, frequency, phase shift and damping ratio coefficients, an observation model consisting of: (1) a damped harmonic oscillation model, (2) an autoregressive model of coloured measurement noise and (3) a stochastic model in the form of the heavy-tailed family of scaled t-distributions is employed and jointly adjusted by means of a generalised expectation maximisation algorithm. Multiple MEMS as part of a geo-sensor network were mounted at different positions of a bridge structure which is precalculated by means of a finite element model (FEM) analysis. At the end, the estimated eigenfrequencies and eigenforms are compared and validated by the estimated parameters obtained from acceleration measurements of high-end accelerometers of type PCB ICP quartz, velocity measurements from a geophone and the FEM analysis. Additionally, the estimated eigenfrequencies and modal damping are compared with a well-known covariance driven stochastic subspace identification approach, which reveals the superiority of our proposed approach. We performed an experiment in two case studies with simulated data and real applications of a footbridge structure and a synthetic bridge. The results show that MEMS accelerometers are suitable for detecting all occurring eigenfrequencies depending on a sampling frequency specified. Moreover, the vibration analysis procedure demonstrates that amplitudes can be estimated in submillimetre range accuracy, frequencies with an accuracy better than 0.1 Hz and damping ratio coefficients with an accuracy better than 0.1 and 0.2 % for modal and system damping, respectively.


Author(s):  
Yen-Po Liu ◽  
Yusuf Altintas

Abstract The structural dynamics of a machine tool at the tool center point characterizes its vibration response and machining stability which affects productivity. The dynamics are mostly dominated by the spindle-holder-tool assembly whose main vibration mode can change during machining due to centrifugal forces, thermal expansion, and gyroscopic moments generated at high spindle speeds. This paper proposes the identification of the spindle's in-process modal parameters: natural frequency, damping ratio and modal constant, by using a limited number of vibration transmissibility and critical chatter stability measurements. The classical inverse stability solution, which tunes the modal parameters to minimize prediction errors in chatter stability limits, is augmented with vibration transmissibility under two methods: (1) transmissibility-enhanced inverse stability solution: the modal parameters are updated to minimize prediction errors in chatter stability, and vibration transmissibility; (2) artificial neural network (ANN)-integrated inverse stability solution: the ANN uses vibration transmissibility to estimate the natural frequency and damping ratio, such that the inverse stability solution only needs to identify the modal constant. While both methods are experimentally validated, it is shown that the transmissibility-enhanced inverse stability solution is a more effective approach than the time-consuming ANN alternative for the estimation of in-process spindle dynamics.


2013 ◽  
Vol 395-396 ◽  
pp. 1008-1014
Author(s):  
Yu Li ◽  
Chao Sun

Chatter has been a problem in CNC machining process especially during machining thin-walled components with low stiffness. For accurately predicting chatter stability in machining Ti6Al4V thin-walled components, this paper establishes a chatter prediction method considering of cutting parameters and tool path. The fast chatter prediction method for thin-walled components is based on physical simulation software. Cutting parameters and tool path is achieved through the chatter stability lobes test and finite element simulation. Machining process is simulated by the physical simulation software using generated NC code. This proposed method transforms the NC physical simulation toward the practical methodology for the stability prediction over the multi-pocket structure milling.


2013 ◽  
Vol 712-715 ◽  
pp. 1241-1247
Author(s):  
Yun Peng Shao ◽  
Xi Jing Zhu ◽  
Meng Liu ◽  
Zhen Liu

The chatter caused by the inner factors of the machining system in the ultrasonic honing process would seriously affect the surface quality of combustion engine. A dynamical model of ultrasonic honing chatter system was established, which involved with ultrasonic honing mechanism and dynamic honing depth, the relationship between the limit honing width and honing speed was deduced based on the theory of regenerative chatter; the simulation was carried out to obtain the effect of different parameters including stiffness coefficient, damping ratio, spindle speed and reciprocation motion speed on the stability limit curve of the chatter system. It can be concluded that the ultrasonic honing chatter system have better stability with low spindle speed, high stiffness and damping ratio, which providing foundation to eliminate ultrasonic honing system chatter in the precision machining of cylinder liner.


2010 ◽  
Vol 66 (4) ◽  
pp. 816-835
Author(s):  
Yoshiaki GOTO ◽  
Kosuke MIZUNO ◽  
Ghosh Prosenjit KUMAR ◽  
Yusuke FUJII

Author(s):  
Zichao Li ◽  
Yanrong Wang ◽  
Xianghua Jiang ◽  
Hang Ye ◽  
Weichao Yang

Abstract When the gear generates a nodal mode shape vibration, there are two directions of possible relative displacement between the corresponding points on the contact surface of the damper ring and the damper groove, which are circumferential direction and axial direction respectively. In this paper, the relative displacement of the damper ring and the damper groove are considered in two directions, and the calculation method of energy dissipation is proposed. When the nodal vibration occurs in the gear, due to the existence of the strain difference between the damper ring and the damper groove on the contact surface, circumferential slip of partial area would occur. The energy dissipation in one vibration cycle is accurately determined by analytical solution. Since the aviation gears are mostly thin-walled structures, the axial displacement is large when resonance occurs. Based on the discrete damper ring model which considers interaction between every segment of the ring, the first-order harmonic balance method is used to calculate the axial displacement of the damper ring under the given gear rim amplitude. And then the hysteresis curve area of each discrete segment on the contact surface is summed to obtain energy dissipation in one vibration cycle. In this paper, based on the energy method, the damping effect of the damper ring is predicted. The damping ratio curve obtained by energy dissipation in two directions is compared and analyzed. The occurrence conditions of the two directions of possible relative displacement and the influence of the damper ring parameters on both situations are summarized.


2010 ◽  
Vol 97-101 ◽  
pp. 1849-1852
Author(s):  
Tong Yue Wang ◽  
Ning He ◽  
Liang Li

Thin-walled structure is easy to vibrate in machining. The dynamic milling model of thin-walled workpiece is analyzed based on the analysis of degrees in two perpendicular directions of machine tool-workpiece system. In high speed milling of 2A12 aluminum alloy, the compensation method based on the modification of inertia effect is proposed and accurate cutting force coefficients are obtained. The machining system is divided into “spindle-cutter” and “workpiece-fixture” two sub-systems and the modal parameters of two sub-systems are acquired via modal analysis experiments. Finally, the stability lobes for high speed milling of 2A12 thin-walled workpiece are obtained by the use of these parameters. The results are verified against cutting tests.


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