Three degrees of freedom chatter stability prediction in the milling process
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DOI 10.1007/s12206-020-0801-4
Journal of Mechanical Science and Technology 34 (9) 2020 Original Article DOI 10.1007/s12206-020-0801-4 Keywords: · Three DOF dynamic model · Improved semi-discretization · Chatter stability · Milling process
Correspondence to: Yuan Wei [email protected]; [email protected]
Citation: Gu, D., Wei, Y., Xiong, B., Liu, S., Zhao, D., Wang, B. (2020). Three degrees of freedom chatter stability prediction in the milling process. Journal of Mechanical Science and Technology 34 (9) (2020) 3489~3496. http://doi.org/10.1007/s12206-020-0801-4
Three degrees of freedom chatter stability prediction in the milling process Dan Gu, Yuan Wei, Bin Xiong, Shulin Liu, Dongfang Zhao and Baoqiang Wang School of Mechatronic Engineering and Automation, Shanghai University, Shanghai 200444, China
Abstract
Chatter in the cutting process has a great influence on workpiece surface quality, machining efficiency, and service life of the machine tool. This work presents three degrees of freedom (DOF) dynamic model applied to tool chatter for thin-walled structures in milling. Combined with dynamic cutting force modelling in the radial, axial and tangential directions, the stability chart was solved by adopting an improved semi-discretization method in time domain. And the stability prediction model considering regenerative effect was validated by cutting tests with specific axial depth of cut and spindle speed. The cutting experimental results performed at different axial depth of cuts were in accordance with predicted stability lobe diagram (SLD). Moreover, the effects of cutting contact angle and radial immersion ratio on SLD were also analyzed. The study results show that the dynamic model could make a good prediction of chatter stability, and the established approach is high efficient in predicting the chatter stability lobe considering the actual situation.
Received September 27th, 2019 Revised
June 20th, 2020
Accepted July 6th, 2020
1. Introduction
† Recommended by Editor No-cheol Park
Thin-walled structures with complex structures are mostly used in aerospace technology. There are many characteristics in NC machining, such as high feed speed, frequent tool axis vector conversion and complex load conditions. Chatter may arise from vibration and fault in the spindle system and inner components of machine tools [1-3]. So it is necessary to analyze and control chatter in the cutting process according to material and geometric characteristics of the workpiece, so as to ensure the surface quality and stability of the machined parts, as well as the service life of the cutter and the machine tool. There is abundant work on chatter stability in milling at the present. Tlusty [4] proposed regenerative chatter of a machine tool in orthogonal cutting. Smith and Tlusty [5] adopted peakto-peak graphs to assess the stable and unstable state of milling operation. Altintaş and Budak [6, 7] developed a practical way to predict the stability lobe by Fourier series components. Eynian et al. [8] employed a dynamic cu
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