Analysis and prediction of the impact of technological parameters on cutting force components in rough milling of AZ31 magnesium alloy

This paper presents the results of experimental study of the AZ31 magnesium alloy milling process. Dry milling was carried out under high-speed machining conditions. First, a stability lobe diagram was determined using CutPro software. Next, experimental studies were carried out to verify the stability lobe diagram. The tests were carried out for different feed per tooth and cutting speed values using two types of tools. During the experimental investigations, cutting forces in three directions were recorded. The obtained time series were subjected to general analysis and analysis using composite multiscale entropy. Modelling and prediction were performed using Statistica Neural Network software, in which two types of neural networks were applied: multi-layered perceptron and radial basis function. It was observed that milling with high cutting speed values allows for component values of cutting force to be lowered as a result of the transition into the high-speed machining conditions range. In most cases, the highest values for the analysed parameters were recorded for the component Fx, whereas the lowest were recorded for Fy. Additionally, the paper shows that a prediction (with the use of artificial neural networks) of the components of cutting force can be made, both for the amplitudes of components of cutting force Famp and for root mean square Frms.

Stability Analysis and Experimental Research on Ultrasonic Cutting of Wave-absorbing Honeycomb Material With Disc Cutter

To address the problem of the poor stability of ultrasonic machining of wave-absorbing honeycomb materials, this paper takes ultrasonic cutting of wave-absorbing honeycomb materials with a disc cutter as the research object and establishes a multi-degree-of-freedom mathematical model of the cutting system based on the relative positions of the tool and the honeycomb material and the motion characteristics of the tool. On this basis, modal analysis of the disc tool and the honeycomb cellular element wall plate is carried out to draw the Lobe diagram of ultrasonic cutting stability, the process experimental parameters are determined according to the solved stability Lobe diagram, and machining stability verification experiments are carried out. The experimental results show that the machining parameters in the stable region of the Lobe diagram result in a neat and clean surface, less fibre pullout, a complete outer substrate, and less tool wear than those in the critical and unstable regions, thus verifying the correctness of the theoretical model and the stability Lobe diagram.

Effects of Machine Tool Spindle Decay on the Stability Lobe Diagram: An Analytical-Experimental Study

An analytical-experimental investigation of machine tool spindle decay and its effects of the system’s stability lobe diagram (SLD) is presented. A dynamic stiffness matrix (DSM)model for the vibration analysis of the OKADA VM500 machine spindle is developed and is validated against Finite Element Analysis (FEA).The model is then refined to incorporate flexibility of the system’s bearings, originally modeled as simply supported boundary conditions, where the bearings are modeled as linear spring elements.The system fundamental frequency obtained from the modal analysis carried on an experimental setup is then used to calibrate the DSM model by tuning the springs’ constants. The resulting natural frequency is also used to determine the 2D stability lobes diagram (SLD) for said spindle. Exploiting the presented approach and calibrated DSM model it is shown that a hypothetical 10% change in the natural frequency would result in a significant shift in the SLD of the spindle system, which should be taken into consideration to ensure chatter-free machining over the spindle’s life cycle.

Effects of Machine Tool Spindle Decay on the Stability Lobe Diagram: An Analytical-Experimental Study

An analytical-experimental investigation of machine tool spindle decay and its effects of the system’s stability lobe diagram (SLD) is presented. A dynamic stiffness matrix (DSM)model for the vibration analysis of the OKADA VM500 machine spindle is developed and is validated against Finite Element Analysis (FEA).The model is then refined to incorporate flexibility of the system’s bearings, originally modeled as simply supported boundary conditions, where the bearings are modeled as linear spring elements.The system fundamental frequency obtained from the modal analysis carried on an experimental setup is then used to calibrate the DSM model by tuning the springs’ constants. The resulting natural frequency is also used to determine the 2D stability lobes diagram (SLD) for said spindle. Exploiting the presented approach and calibrated DSM model it is shown that a hypothetical 10% change in the natural frequency would result in a significant shift in the SLD of the spindle system, which should be taken into consideration to ensure chatter-free machining over the spindle’s life cycle.

Analysis of the Tool Stick-Out Influence on Machining Chatter

Increased stability in machining processes is highly desired by all machining industries when vibrations and specially chatter occur. This phenomenon is defined as a self-excited vibration that occurs due to the regeneration of waviness of the workpiece surface. In machining industry, the trend is to rely on the trial and error method or mere experience when deciding the machining spindle speeds, depths of cut and tool stick-outs, all of which are parameters directly related to chatter occurrence. Currently, the shortest possible tool stick-out is chosen by default, but literature has proven that longer stick-outs may bring some advantages when it comes to material removal rates. Aiming to prove this theory, this paper will discuss the influence of the tool stick-out on machining chatter occurrence. To that end, the effect of the tool stick-out on the modal parameters of the system, on the Stability Lobe Diagram (SLD) and on productivity will be analysed. Therefore, a number of Tap-Tests to different tool/tool-holder/stick-out combinations have been performed, in order to gather the data (FRFs and SLDs) where the analysis is based on. Last but not least, some machining tests have been conducted aiming to compare the theoretical chatter occurrence conditions, provided by the SLD, with the experimental ones. For that, two Al5083 workpieces have been slot milled under different cutting conditions, facilitating the unexpected results wherein the conclusions have been based upon.

Pendekatan alternatif dalam menghasilkan stability lobes diagram untuk memprediksi getaran chatter pada proses pemesinan berdinding tipis

Machining is widely used for finishing process of the entire manufacturing process chain. Machining process of thin plate, however, is not an easy task. This is because excessive vibration (chatter) can rise during operation. To predict the chatter vibration, a stability lobe diagram (SLD) is usually utilized which is strongly dependent on the frequency response function (FRF). This paper proposes an alternative approach for analyzing modal analysis by finite element method (FEM) to obtain FRF during machining thin-walled plate. The result showed that simulation result has good enough agreement to experimental result with slight differences caused by the assumed boundary conditions in the FEM process. This approach can be used to reduce the use of hammering tests and can be used to get FRF of multi stage working.

Measurement-Based Modal Analysis and Stability Prediction on Turn-Milling of Hollow Turbine Blade

Hollow blades with honeycomb structures are increasingly used in the turbine engines for reducing weight and saving costs. The hollow blade is a typical thin-walled structural part with low stiffness, the machining system of which is often unstable and likely to chatter. The most effective solution to avoid the machining chatter is to guide the hollow blade to be machined in a stable machining zone. This paper proposes a measurement-based approach for modal analysis and stability prediction of turn-milling hollow blade. The impact test was carried out to achieve the FRF curves on the hollow blade and the milling tool. An extremum method was employed to obtain an equivalent FRF curve, from which the modal parameters involving the natural frequency, damping ratio, and stiffness were computed. Afterwards, the semidiscretization method was used to draw a stability lobe diagram to predict the stability when turn-milling hollow blades. The experimental results confirm the feasibility of the predicted stability lobe diagram.

Research of Chatter Suppression in Turning Operation with Process Damping using Stability Lobe Diagram

This paper presents a chatter detection technique based on the stability of the measured Ra and Rz values of process damping and surface roughness in low cutting speed activities. In practice, process damping during machining procedures is hard to predict and identify due to the model and technique of limitation. The impact of cutting conditions on process damping in turning with P20 steel pre-hardened metal in terms of cutting velocity, feed rate and cutting depth was explored by the Stability Lobe Diagram method. A CNC turning machine was used in dry turning procedures with carbide insert. The highest and minimum value of natural frequencies and damping ratios were evaluated by modal testing and the stability lobe diagram analysis was applied. It is concluded that in the same region of the Stability Lobe Diagram, the chatter and measured surface roughness values were correlated and shown to have strong consensus.

Discrete Time-Delay Optimal Control Method for Experimental Active Chatter Suppression and Its Closed-Loop Stability Analysis

Chatter is a self-excited and unstable vibration phenomenon during machining operations, which affects the workpiece surface quality and the production efficiency. Active chatter control has been intensively studied to mitigate chatter and expand the boundary of machining stability. This paper presents a discrete time-delay optimal control method for chatter suppression. A dynamical model incorporating the time-periodic and time-delayed characteristic of active chatter suppression during the milling process is first formulated. Next, the milling system is represented as a discrete linear time-invariant (LTI) system with state-space description through averaging and discretization. An optimal control strategy is then formulated to stabilize unstable cutting states, where the balanced realization method is applied to determine the weighting matrix without trial and error. Finally, a closed-loop stability lobe diagram (CLSLD) is proposed to evaluate the performance of the designed controller based on the proposed method. The CLSLD can provide the stability lobe diagram with control and evaluate the performance and robustness of the controller cross the tested spindle speeds. Through many numerical simulations and experimental studies, it demonstrates that the proposed control method can make the unstable cutting parameters stable with control on, reduce the control force to 21% of traditional weighting matrix selection method by trial and error in simulation, and reduce the amplitude of chatter frequency up to 78.6% in experiment. Hence, the designed controller reduces the performance requirements of actuators during active chatter suppression.