Prediction of chatter stability for enhanced productivity in parallel orthogonal turn-milling
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ORIGINAL ARTICLE
Prediction of chatter stability for enhanced productivity in parallel orthogonal turn-milling Zhongpeng Zheng 1 & Xin Jin 1 & Yewang Sun 1 & Zhijing Zhang 1 & Hongchang Sun 1 & Qiming Li 1 Received: 27 November 2019 / Accepted: 28 August 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract To increase productivity and the material removal rate, an increasing number of factories have been employing multiple tools for simultaneous cutting. Among these tools is parallel orthogonal turn-milling, which is an important parallel-processing method. However, a dynamic interaction occurs during the cutting processes due to the waviness induced on the shared cutting surface and the dynamic coupling through the machine structure, creating machining vibrations, or chatter, which affect the quality of the machined surface. Therefore, to reduce or avoid the vibration problem during the cutting process, chatter stability of parallel orthogonal turn-milling was examined in this study. Initially, a chatter mechanism model of parallel orthogonal turn-milling was designed, and the limit-critical axial depth of the cut formula was obtained. Next, the model parameters of the machine tool were obtained based on the hammer test method. A parallel orthogonal turn-milling stability lobe diagram (SLD) with tool tip runout was constructed. Finally, the experimental results were verified on a high-efficiency turn-milling machine tool. The results showed that chatter can be predicted for parallel orthogonal turn-milling and an SLD can provide a reference for the selection of machining parameters. In addition, the SLD can also guide the formulation of processing technology specifications. Our results are extremely significant for ongoing research in the field of machining methods. Keywords Chatter stability . Enhanced productivity . Material removal . Orthogonal turn-milling . Stability lobe diagram
1 Introduction The high-efficiency micro-turn-milling machine tool has simultaneous multi-tool and dual-spindle machining functions. As a typical machining method, parallel orthogonal turn-milling has the advantage of two milling cutters simultaneously machining a workpiece. This approach can achieve a higher material removal rate and greatly improve machining efficiency. As with conventional machining methods, chatter can also occur during parallel orthogonal turn-milling, thereby affecting the machining quality of the workpiece and the life of the tool. Therefore, it is necessary to improve the dynamic stability of high-efficiency turn-milling machine tools and reduce or avoid vibration during cutting [1–3]. Chatter is a strong self-excited vibration generated during the cutting process. Chatter can seriously affect cutting efficiency, reduce the machining accuracy of parts, and
* Xin Jin [email protected] 1
School of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China
damage tools. As early as 1907, Taylor proposed the concept of processing chatter [4]. More recently, Tlusty et
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