Control of milling process dynamics through a mechatronic tool holder with purposely designed Joint Interface

Machine tool joints have significant influence on the dynamic characteristics of the machine tool and therefore on the response of the machining system to excitations from the cutting process. In cases of unstable response, generally described as chatter, surface quality of a machined work-piece and tool life deteriorate significantly. This paper presents a novel way of exploiting joints in order to control the dynamic response of the system, by integrating a mechatronic tool holder (Joint Interface Module - JIM) in the machine tool. This system has a purposely designed joint interface with controllable natural characteristics (stiffness and damping). These characteristics are controlled by altering the applied preload on the internal joint interface of the tool holder. The preload on the joint interface is controlled by pneumatic means. In doing so, a milling process during which the stability limit was exceeded became stable during the machining process, without alteration of the process parameters.

[1]  Y. S. Tarng,et al.  Design of a dynamic vibration absorber against vibrations in turning operations , 2001 .

[2]  Yusuf Altintas,et al.  Modeling and identification of tool holder–spindle interface dynamics , 2007 .

[3]  G. G. Stokes.  "J." , 1890, The New Yale Book of Quotations.

[4]  C. Andrew,et al.  Paper 22: Metal Surfaces in Contact under Normal Forces: Some Dynamic Stiffness and Damping Characteristics: , 1967 .

[5]  P ? ? ? ? ? ? ? % ? ? ? ? , 1991 .

[6]  Fathy Ismail,et al.  Active suppression of chatter in peripheral milling. Part II. Application of fuzzy control , 1996 .

[7]  B. Denkena,et al.  Tool deflection compensation with an adaptronic milling spindle , 2007 .

[8]  Cornel Mihai Nicolescu,et al.  Experimental analysis of the CNx nano-damping material’s effect on the dynamic performance of a milling process , 2013 .

[9]  Lorenzo Daghini,et al.  Improving Machining System Performance through designed-in Damping : Modelling, Analysis and Design Solutions , 2012 .

[10]  Kai Cheng,et al.  Machining dynamics: Fundamentals, applications and practices , 2008 .

[11]  I. Garitaonandia,et al.  An active system of reduction of vibrations in a centerless grinding machine using piezoelectric actuators , 2007 .

[12]  Jürgen Fleischer,et al.  High Performance Machining Enabled by Adaptive Machine Components , 2015 .

[13]  Eugene I. Rivin.  Contact (Joint) Stiffness and Damping , 2010 .

[14]  Liang Mi,et al.  Effects of preloads on joints on dynamic stiffness of a whole machine tool structure , 2012 .

[15]  Fathy Ismail,et al.  Active suppression of chatter in peripheral milling Part 1. A statistical indicator to evaluate the spindle speed modulation method , 1995 .

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

[17]  Christian Brecher,et al.  Tooling Structure: Interface between Cutting Edge and Machine Tool , 2000 .

[18]  Yusuf Altintas,et al.  Modeling of spindle-bearing and machine tool systems for virtual simulation of milling operations , 2007 .

[19]  Yoshimi Ito,et al.  Modular Design for Machine Tools , 2008 .

[20]  Amir Rashid.  On passive and active control of machining system dynamics : analysis and implementation , 2005 .

[21]  A. Polycarpou,et al.  Measurement and Modeling of Normal Contact Stiffness and Contact Damping at the Meso Scale , 2005 .

[22]  Constantinos Frangoudis,et al.  Controlling the dynamic characteristics of machining systems through consciously designed joint interfaces , 2014 .

[23]  Berend Denkena,et al.  TOOL ADAPTOR FOR ACTIVE VIBRATION CONTROL IN TURNING OPERATIONS , 2004 .

[24]  Guillem Quintana,et al.  Chatter in machining processes: A review , 2011 .

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

[26]  Christian Brecher,et al.  Damping models for machine tool components of linear axes , 2013 .

[27]  K. K. Padmanabhan,et al.  Prediction of damping in machined joints , 1992 .

[28]  Chinedum E. Okwudire,et al.  Dynamic stiffness enhancement of direct-driven machine tools using sliding mode control with disturbance recovery , 2009 .

[29]  John S. Agapiou,et al.  Metal Cutting Theory and Practice , 1996 .

[30]  J. H. Wang,et al.  Suppression of Chatter Vibration of a CNC Machine CENTRE—AN Example , 1996 .

[31]  N. K. Mehta,et al.  An investigation of tool wear and the vibration spectrum in milling , 1983 .

[32]  Eugene I. Rivin,et al.  Stiffness and Damping in Mechanical Design , 1999 .

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

[34]  Amir Rashid,et al.  Constraining the shear strain in viscoelastic materials and utlization of the “incompressible” properties for damping treatment in hybrid joint interface module to improve their effect for vibration control in machining , 2016 .

[35]  Yusuf Altintas,et al.  Analytical Prediction of Stability Lobes in Milling , 1995 .