Analytical Prediction of Part Dynamics for Machining Stability Analysis

An analytical procedure is developed to predict workpiece dynamics in a complete machining cycle in order to obtain frequency response functions (FRF) which are needed in chatter stability analyses. For this purpose, a structural modification method which is an efficient tool for updating FRFs is used. The removed mass by machining is considered as a structural modification in order to determine the FRFs at different stages of the process. The method is implemented in a computer code and demonstrated on different geometries. The predictions are compared and verified by FEA. Predicted FRFs are used in chatter stability analyses, and the effect of part dynamics on stability is studied. Different cutting strategies are compared for increased chatter free material removal rates considering part dynamics.

[1]  Yusuf Altintas,et al.  Analytical Prediction of Chatter Stability in Milling—Part I: General Formulation , 1998 .

[2]  H. E. Merritt.  Theory of Self-Excited Machine-Tool Chatter: Contribution to Machine-Tool Chatter Research—1 , 1965 .

[3]  Jean-François Debongnie,et al.  Providing stability maps for milling operations , 2007 .

[4]  Tony L. Schmitz,et al.  Tool Point Frequency Response Prediction for High-Speed Machining by RCSA , 2001 .

[5]  B. Kuran,et al.  A MODAL SUPERPOSITION METHOD FOR NON-LINEAR STRUCTURES , 1996 .

[6]  Tony L. Schmitz,et al.  Predicting High-Speed Machining Dynamics by Substructure Analysis , 2000 .

[7]  Erhan Budak,et al.  A Modeling Approach for Analysis and Improvement of Spindle-Holder-Tool Assembly Dynamics , 2006 .

[8]  Barry N. Lewendon,et al.  Machine Tool Vibration , 1981, Other Conferences.

[9]  F. Koenigsberger,et al.  Machine Tool Structures , 1969 .

[10]  Dirk Biermann,et al.  Modeling regenerative workpiece vibrations in five-axis milling , 2008, Prod. Eng..

[11]  H. N. Özgüvena,et al.  Effect analysis of bearing and interface dynamics on tool point FRF for chatter stability in machine tools by using a new analytical model for spindle–tool assemblies , 2006 .

[12]  Thomas J. Royston,et al.  Identification of structural non-linearities using describing functions and the Sherman-Morrison method , 2005 .

[13]  I. E. Minis,et al.  A New Theoretical Approach for the Prediction of Machine Tool Chatter in Milling , 1993 .

[14]  Yusuf Altintas,et al.  Analytical Prediction of Chatter Stability in Milling—Part II: Application of the General Formulation to Common Milling Systems , 1998 .

[15]  Pascal Ray,et al.  Stability-based spindle speed control during flexible workpiece high-speed milling , 2008 .

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

[17]  H. Nevzat Özgüven,et al.  Structural modifications using frequency response functions , 1990 .

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

[19]  Jiří Tlustý,et al.  Manufacturing processes and equipment , 1999 .

[20]  A. Ertürka,et al.  Analytical modeling of spindle–tool dynamics on machine tools using Timoshenko beam model and receptance coupling for the prediction of tool point FRF , 2006 .

[21]  Gilles Dessein,et al.  Integration of dynamic behaviour variations in the stability lobes method: 3D lobes construction and application to thin-walled structure milling , 2006 .