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TECHNICAL PAPERS

A Stability Solution for the Axial Contour-Turning Process

[+] Author and Article Information
Rohit G. Reddy, O. Burak Ozdoganlar, Shiv G. Kapoor, Richard E. DeVor, Xinyu Liu

Department of Mechanical and Industrial Engineering, University of Illinois at Urbana-Champaign, Urbana, IL 61801-2906

J. Manuf. Sci. Eng 124(3), 581-587 (Jul 11, 2002) (7 pages) doi:10.1115/1.1480415 History: Received October 01, 2000; Revised October 01, 2001; Online July 11, 2002
Copyright © 2002 by ASME
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References

Reddy,  R. G., Kapoor,  S. G., and DeVor,  R. E., 2000, “A Mechanistic Force Model for Contour Turning,” ASME J. Manuf. Sci. Eng. 123, 3.
Babinski, A., 2000, “Control of Voice-Coil Actuator with Application to Cam Turning,” PhD thesis, University of Illinois at Urbana-Champaign.
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Merritt,  H. E., 1965, “Theory of Self-Excited Chatter,” ASME J. Eng. Ind., 87, pp. 447–454.
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Budak,  E., and Altintas,  Y., 1998, “Analytical Prediction of Chatter Stability in Milling-Part 1: General Formulation,” ASME J. Dyn. Syst., Meas., Control, 120, pp. 22–30.
Jayaram, S., 1996, “Stability and Vibration Analysis of Turning and Face Milling Processes,” PhD thesis, University of Illinois at Urbana-Champaign.
Ozdoganlar, O. B., and Endres, W. J., 1998, “An Analytical Stability Solution for the Turning Process with Depth-Direction Dynamics and Corner-Radiused Tooling,” Symp. on Advances in Modeling, Monitoring, and Control of Machining Systems, Vol. DCS-64, pp. 511–518.
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Ozdoganlar,  O. B., and Endres,  W. J., 2000, “An Analytical Representation of Chip Area for Corner-Radiused Tools under Both Depth-of-Cut and Feed Variations,” ASME J. Manuf. Sci. Eng., 122(4), pp. 660–665.
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Figures

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A schematic of axial contour turning process
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Equivalent triangular chip for stability analysis
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Dynamic chip-area variations in the equivalent chip
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(a) Tool-fixture and workpiece for the contour turning stability experiments, and (b) a schematic of the workpiece with concave-convex contours
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Variation of critical depth of cut versus spindle speed at various tool locations
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Variation of critical depth of cut versus tool path in axial contour turning
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Stability limit in spindle speed versus tool path plane for d=1 mm and d=0.5 mm with ft=0.1 mm/rev and ρ=30degrees
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Resultant force data along the cut while machining at (a) 3200 rpm and (b) 5000 rpm
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Experimental and simulated stability data for machining with ρ=30 deg at (a) 2350 rpm, (b) 3200 rpm, (c) 3900 rpm, and (d) 5000 rpm
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Experimental and simulated stability data for machining with ρ=0 deg at (a) 6000 rpm and (b) 4000 rpm
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Experimental and simulated stability data for machining with ρ=90 deg. (minimum stability at toolpath location of 92 deg)
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Stability limit diagrams in the spindle speed versus tool path plane for (a) ρ=0deg. and d=0.5 mm depth of cut (b) ρ=90deg and d=2.5 mm depth of cut
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Variation of critical speed vs. tool path and the spindle speed selection schemes
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The cross-section of an automotive wheel—rim portion
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Tool path for the rim portion of the wheel under consideration
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Stability of the automotive wheel for dr=0.5 mm and dr=1.5 mm with ft=0.3 mm per rev
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Stability of the automotive wheel in the radial depth of cut versus spindle speed plane at 25 mm and 33 mm axial (tool path) distances

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