Chatter avoidance in cutting highly flexible workpieces

Abstract Robust stability analysis of turning is presented for flexible workpiece. The varying dynamic properties due to the material removal process is modelled by means of finite element method. The Frequency Response Function is traced along tool position. The results show significant change in the natural frequency and modal stiffness, which have strong influence on regenerative chatter vibration. Different sections of the multiple-parameter stability lobe diagram are presented and validated with experimental results. The robust stable parameters of initial diameter and chip width are identified for which no chatter occurs along the whole tool position for any spindle speed.

[1]  Yusuf Altintas,et al.  Modeling and avoidance of static form errors in peripheral milling of plates , 1995 .

[2]  Tony L. Schmitz,et al.  Tool Length-Dependent Stability Surfaces , 2004 .

[3]  Christian Brecher,et al.  Chatter suppression techniques in metal cutting , 2016 .

[4]  L. Taner Tunç,et al.  Prediction of workpiece dynamics and its effects on chatter stability in milling , 2012 .

[5]  Francisco J. Campa,et al.  Chatter avoidance in the milling of thin floors with bull-nose end mills: Model and stability diagrams , 2011 .

[6]  Gilles Dessein,et al.  INFLUENCE OF MATERIAL REMOVAL ON THE DYNAMIC BEHAVIOR OF THIN-WALLED STRUCTURES IN PERIPHERAL MILLING , 2004 .

[7]  Gábor Stépán,et al.  Cumulative Surface Location Error for Milling Processes Based on Tool-tip Frequency Response Function , 2016 .

[8]  Gábor Stépán,et al.  Surface Error and Stability Chart of Beam-Type Workpiece in Milling Processes , 2016 .

[9]  Dirk Biermann,et al.  A general approach to simulating workpiece vibrations during five-axis milling of turbine blades , 2010 .

[10]  Manfred Weck,et al.  Chatter Stability of Metal Cutting and Grinding , 2004 .

[11]  Gábor Stépán,et al.  Estimation of Safe Chatter-free Technological Parameter Regions for Machining Operations , 2016 .

[12]  Zoltan Dombovari,et al.  On the Global Dynamics of Chatter in the Orthogonal Cutting Model , 2011 .

[13]  Philippe Lorong,et al.  Dynamic Study of Thin Wall Part Turning , 2011 .

[14]  Francisco J. Campa,et al.  Stability limits of milling considering the flexibility of the workpiece and the machine , 2005 .

[15]  Gilles Dessein,et al.  Toolpath dependent stability lobes for the milling of thin-walled parts , 2008 .

[16]  Ramezanali Mahdavinejad,et al.  Finite element analysis of machine and workpiece instability in turning , 2005 .

[17]  Yusuf Altintas,et al.  Rapid evaluation and optimization of machine tools with position-dependent stability , 2013 .

[18]  S. A. Tobias.  Machine-tool vibration , 1965 .

[19]  Philippe Lorong,et al.  Variable Compliance-related Aspects of Chatter in Turning Thin-walled Tubular Parts , 2015 .

[20]  Yusuf Altintas,et al.  Frequency Domain Updating of Thin-Walled Workpiece Dynamics Using Reduced Order Substructuring Method in Machining , 2017 .

[21]  Qinghua Song,et al.  Prediction of simultaneous dynamic stability limit of time–variable parameters system in thin-walled workpiece high-speed milling processes , 2011 .