Frequency response function simulation and evaluating in boring

Finite element method of simulating frequency response function (FRF) for boring tool in LS-Dyna solver is investigated in this work. Nowadays, computer numerical simulation allows to obtain FRF using different materials model with high precision compared to real experiments with sensors like impact hammer testing. This function is used in construction of stability lobe diagrams that allows operator of machining center to avoid chatter self-excited vibrations. Such vibration is led to decreasing of productivity and quality in cutting of metals and other materials. Amplitude and phase angle for the model is obtained from LS-Dyna result interpreter, that reads binary files, created during simulation by the program. Amplitude and phase angle of frequency response function are depending on dynamic stiffness of machining system. Real and imaginary part of frequency response function have been obtained during simulation. With luck of dynamic stiffness amplitudes of response increases.

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.

EFFICIENT DETERMINATION OF STABILITY LOBE DIAGRAMS DEPLOYING AN AUTOMATED, DATA-BASED ONLINE NC PROGRAM ADAPTION

Process instabilities due to regenerative chatter pose significant limitations on the achievable material removal rates and thus on the profitability of machining operations. Stability lobe diagrams serve to exploit the maximum yet stable cutting depth and can be determined either analytically or experimentally. While analytical approaches suffer from inaccuracies because of the assumptions made for the specific models, experimental stability lobe diagrams require extensive cutting tests. Therefore, this paper introduces a new automated experimental method for determining stability lobe diagrams in milling with reduced effort regarding time. A closed-loop system is designed, containing a sensor-based online chatter detection along with a strategy to set parameters for subsequent cuts based on the stability boundaries known at each iteration. Both cuts with continuously increasing cutting depth and varied spindle speed are deployed to ensure fast detection of stability limits. The method is tested for a slot milling use case and the results are compared to a conventionally obtained stability lobe diagram yielding a significantly reduction in required time (-90 %) and resources (-67 %) whilst maintaining good accuracy. The reduced effort qualifies the proposed method as a tool to rapidly deliver maximum productive yet stable cutting parameters for optimization of existing or enhanced planning of new manufacturing processes.

Моделювання амплітудно-фазової частотної функції і її оцінка при розто- чуванні

Finite element method of simulating frequency response function (FRF) for boring tool in LS-Dyna solver is investigated in this work. Nowadays, computer numerical simulation allows to obtain FRF using different materials model with high precision compared to real experiments with sensors like impact hammer testing. This function is used in construction of stability lobe diagrams that allows operator of machining center to avoid chatter self-excited vibrations. Such vibration is led to decreasing of productivity and quality in cutting of metals and other materials. Amplitude and phase angle for the model is obtained from LS-Dyna result interpreter, that reads binary files, created during simulation by the program. Amplitude and phase angle of frequency response function are depending on dynamic stiffness of machining system.

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.

An updated Simpson-Based Method for Chatter Stability Prediction in Milling

An updated Simpson-based method (USBM) is presented for milling stability analysis. Firstly, the delay differential equation (DDE) is employed to describe the milling process mathematically. Then, the tooth passing period is divided into two subintervals, i.e., the free and forced vibration intervals. Only the forced vibration interval is divided into many equal small-time intervals. Subsequently, the DDE in the state space is solved based on direct integration. By combining the two-step Simpson method and the semi-discretization method, the state transition matrix of the milling system is constructed. The comparison of convergence rate is conducted to validate the accuracy of the proposed method. The results show that the proposed method converges faster than the benchmark methods. The stability lobe diagrams for the one degree of freedom (one-DOF) and two degrees of freedom (two-DOF) milling systems are also obtained by different methods for further evaluation. Meanwhile, the computation time analysis is also carried out. It is revealed that the proposed USBM has advantages in both accuracy and efficiency. Besides, the proposed method can accurately and efficiently predict the stability of milling with both large and low immersion conditions.

TIME DOMAIN STUDY ON THE CONSTRUCTION MECHANISM OF MILLING STABILITY LOBE DIAGRAMS WITH MULTIPLE MODES

The stability lobe diagram (SLD) is an important expression way of milling stability prediction result. The SLD obtained by only selecting the most flexible mode fails to predict the chatter if the milling process is dominated by multiple modes. To reveal the relationship between the SLD with multiple modes and the SLDs corresponding to each single mode, this paper studies the construction mechanism of the SLD with multiple modes by using a time domain method. First, the milling dynamic model of the tool with multiple modes is established. Then, the numerical method based on the Newton-Cotes rules is used to solve the milling dynamic model with multiple modes whose solution is in the form of the SLD. It shows that the SLD with multiple modes can be approximated by using the lowest envelope of the SLDs corresponding to each single mode. Finally, two study cases are adopted to verify the construction mechanism of the SLD with multiple modes. To verify the correctness of the SLD with multiple modes, a series of milling tests are carried out. The experimental results agree with the simulation results, which means the proposed time domain method can reveal the construction mechanism of the SLD with multiple modes.

Time Domain Study on the Construction Mechanism of Milling Stability Lobe Diagrams With Multiple Modes

The stability lobe diagram (SLD) is an important expression way of milling stability prediction result. The SLD obtained by only selecting the most flexible mode fails to predict the chatter if the milling process is dominated by multiple modes. To reveal the relationship between the SLD with multiple modes and the SLDs corresponding to each single mode, this paper studies the construction mechanism of the SLD with multiple modes by using the time domain method. First, the milling dynamic model of the tool with multiple modes is established. Then, the numerical method based on the Newton-Cotes rules is used to solve the milling dynamic model with multiple modes whose solution is in the form of the SLD. It shows that the SLD with multiple modes can be approximated by using the lowest envelope of the SLDs corresponding to each single mode. Finally, two study cases are adopted to verify the construction mechanism of the SLD with multiple modes. To verify the correctness of the SLD with multiple modes, a series of milling tests are carried out. The experimental results agree with the simulation results, which means the proposed time domain method can reveal the construction mechanism of the SLD with multiple modes.

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.