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

Self-excited vibration of the tool, regenerative chatter, can be predicted and eliminated if the stability lobe diagram of the spindle–holder–tool assembly is known. Regardless of the approach being used, analytically or numerically, forming the stability lobe diagram of an assembly implies knowing the point frequency response function (FRF) in receptance form at the tool tip. In this paper, it is aimed to study the effects of spindle–holder and holder–tool interface dynamics, as well as the effects of individual bearings on the tool point FRF by using an analytical model recently developed by the authors for predicting the tool point FRF of spindle–holder–tool assemblies. It is observed that bearing dynamics control the rigid body modes of the assembly, whereas, spindle–holder interface dynamics mainly affects the first elastic mode, while holder–tool interface dynamics alters the second elastic mode. Individual bearing and interface translational stiffness and damping values control the natural frequency and the peak of their relevant modes, respectively. It is also observed that variations in the values of rotational contact parameters do not affect the resulting FRF considerably, from which it is concluded that rotational contact parameters of both interfaces are not as crucial as the translational ones and therefore average values can successfully be used to represent their effects. These observations are obtained for the bearing and interface parameters taken from recent literature, and will be valid for similar assemblies. Based on the effect analysis carried out, a systematic approach is suggested for identifying bearing and interface contact parameters from experimental measurements.

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

[2]  Tony L. Schmitz,et al.  Receptance Coupling for High-Speed Machining Dynamics Prediction , 2003 .

[3]  J. Tlusty,et al.  Basic Non-Linearity in Machining Chatter , 1981 .

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

[5]  Evren Burcu Kivanc,et al.  Structural modeling of end mills for form error and stability analysis , 2004 .

[6]  Yusuf Altintas,et al.  Receptance coupling for end mills , 2003 .

[7]  Erhan Budak,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 .

[8]  S. Smith,et al.  Efficient simulation programs for chatter in milling , 1993 .

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

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

[11]  J. Tlusty,et al.  Dynamics of High-Speed Milling , 1986 .

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

[13]  Ioannis Minis,et al.  Analysis of Linear and Nonlinear Chatter in Milling , 1990 .

[14]  Hasan Ozguven,et al.  A new method for harmonic response of non-proportionally damped structures using undamped modal data , 1987 .

[15]  Tony L. Schmitz,et al.  Improving High-Speed Machining Material Removal Rates by Rapid Dynamic Analysis , 2001 .

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

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

[18]  Tony L. Schmitz,et al.  Three-Component Receptance Coupling Substructure Analysis for Tool Point Dynamics Prediction , 2005 .

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