Time Domain Stability Analysis for Machining Processes
In this paper, a time-domain simulation approach for stability analysis of machining processes is presented. Stability limits are detected by a new criterion. To ensure the reliability and the effectiveness of the proposed approach, the stability of the t
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Abstract In this paper, a time-domain simulation approach for stability analysis of machining processes is presented. Stability limits are detected by a new criterion. To ensure the reliability and the effectiveness of the proposed approach, the stability of the turning process is first studied, and then compared to the well-known semi analytical frequency-domain approach of Budak and Altintas, which gives exact stability predictions in this case. However, the proposed time-domain approach in milling process provides more conservative and realistic results in stability predictions. These results highlight the lack of precision of the classical frequencydomain approach for which several simplifying assumptions are made. Keywords Turning
Milling Stability lobes Chatter
1 Introduction The productivity is a key issue in machining operations. It depends on the cutting parameters but it is restricted by the phenomenon of chatter instability.
A. Maamar (&) B.C. Bouzgarrou V. Gagnol Institut Pascal, Université de Clermont, Campus Universitaire de Clermont-Ferrand, Sigma-Clermont BP 10448, 63175 Aubière Cedex, France e-mail: [email protected] B.C. Bouzgarrou e-mail: [email protected] V. Gagnol e-mail: [email protected] R. Fathallah Ecole Nationale D’Ingénieurs de Sousse (ENISo), Technopole de Sousse, Université de Sousse, BP 264 Sousse Erriadh 4023, Tunisie, Tunisia e-mail: [email protected] © Springer International Publishing Switzerland 2017 T. Fakhfakh et al. (eds.), Advances in Acoustics and Vibration, Applied Condition Monitoring 5, DOI 10.1007/978-3-319-41459-1_8
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Chatter has been widely studied (Altintaş and Budak 1995; Tobias and Fishwick 1958). It consists in a feedback mechanism for the growth of the self-excited vibrations due to the vibrations in chip thickness, cutting force and tool vibrations (Gagnol et al. 2011). Many researches are performed to model this phenomenon, in order to avoid it (Altintaş and Budak 1995; Merritt 1965; Tobias and Fishwick 1958). These studies have led to graphic charts, commonly known as stability lobe diagrams, showing the stability limits as a function of chip thickness and spindle speed. In 1983, Tlusty used a time domain simulation to predict machining stability of helical end mills and to develop the stability diagrams (Tlusty et al. 1983). In 1991, Smith highlighted the use of peak-to-peak force diagrams to plot cutting stability limit (Smith and Tlusty 1993; Tlusty et al. 1991). Altintas and Budak, in 1995, developed an analytical approach to develop the stability lobes in milling (Altintaş and Budak 1995). In the present study, machining stability prediction is developed by a time-domain simulation approach. The proposed approach allows evaluating stability prediction error attached to the hypotheses made in the frequency domain by Altintas and Budak.
2 Stability Prediction in Turning In this section, a stability analysis in turning process is performed based on a time-dom
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