Stability analysis of 2-DOF milling dynamics for simultaneously varying tooth pitch and spindle speed with helix angle e
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ORIGINAL ARTICLE
Stability analysis of 2-DOF milling dynamics for simultaneously varying tooth pitch and spindle speed with helix angle effect Wen-An Yang 1 & Chao Huang 1 Received: 3 February 2020 / Accepted: 5 August 2020 / Published online: 20 August 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Suppression of self-excited vibrations in their design and incipient stages is vital for assuring surface finish and machining efficiency in the precision machining process. Various cutting vibration suppression methods (e.g., variable tooth pitch and variable spindle speed) have been designed for suppressing regenerative chatter. However, variable parameter-based cutting vibration suppression models have mostly been developed separately with the other parameter assumed to be constant. In addition, these methods failed to provide detailed helix angle information required by a machining practitioner to determine which helix angle degree or group of helix angle degrees would have matched the stability of milling cutters. Moreover, only a single degree of freedom (1-DOF) milling system was adopted; thus, these methods cannot account for two degrees of freedom (2-DOF) and higher milling system. This study proposes a helix angle-based 2-DOF milling model with simultaneous tooth pitch and spindle speed variation to deal with these aforementioned problems. Experimental results showed that the proposed model can be effectively and efficiently applied to the prediction of the regenerative chatter stability for not only 1-DOF but also 2-DOF milling system. Empirical comparisons indicated that the proposed model outperformed the existing methods in stability prediction, while also offering stable area enlargement capability that facilitates cutting vibration suppression. A numerical example is presented to illustrate the usage of the proposed model. Keywords Non-uniform tooth pitch . Spindle speed variation . Chatter stability prediction . Regenerative chatter suppression . Full-discretization method
1 Introduction Milling machining processes are comprehensively utilized in aerospace industry for machining high added value components such as impellers, blades, and blisks that are usually made of hard-to-cut materials. In the milling processes, regenerative chatter is an undesirable phenomenon that adversely affects the surface quality, increases the rate of tool wear, and even shortens the life of machine tool [1, 2]. Consequently, control of chatter vibration and machining instability is a critical and complementary tool to milling operations.
* Wen-An Yang [email protected] 1
National Key Laboratory of Science and Technology on Helicopter Transmission, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China
Over the past decades, intensive efforts have been devoted to the development of stability lobe diagrams (SLDs) as an effective tool to prediction of regenerative chatter stability. Altintas and Budak [3] used an analytical method (ZOA) to resolve the problem of predicting
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