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TECHNICAL PAPERS

An Improved Time Domain Simulation for Dynamic Milling at Small Radial Immersions

[+] Author and Article Information
Marc L. Campomanes

Manufacturing Engineering Development, Pratt & Whitney Canada, Longueuil, Québec, Canadae-mail: marc.campomanes@pwc.ca

Yusuf Altintas

Department of Mechanical Engineering, University of British Columbia, Vancouver, B.C., Canadae-mail: altintas@mech.ubc.ca

J. Manuf. Sci. Eng 125(3), 416-422 (Jul 23, 2003) (7 pages) doi:10.1115/1.1580852 History: Received March 01, 2001; Revised November 01, 2002; Online July 23, 2003
Copyright © 2003 by ASME
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References

Kline,  W. A., DeVor,  R. E., and Shareef,  I. A., 1982, “The Prediction of Surface Accuracy in End Milling,” ASME J. Eng. Ind., 104, pp. 272–278.
Kline,  W. A., and DeVor,  R. E., 1983, “The Effect of Runout on Cutting Geometry and Forces in End Milling,” Int. J. Mach. Tool Des. Res., 23, pp. 123–140.
Ranganath,  S., Narayanan,  K., and Sutherland,  J. W., 1999, “The Role of Flank Face Interference in Improving the Accuracy of Dynamic Force Predictions in Peripheral Milling,” ASME J. Manuf. Sci. Eng., 121, pp. 593–599.
Tlusty,  J., and Ismail,  F., 1981, “Basic Nonlinearity in Machining Chatter,” CIRP Ann., 30, pp. 21–25.
Tlusty,  J., 1986, “Dynamics of High Speed Milling,” ASME J. Eng. Ind., 108, pp. 59–67.
Smith,  S., and Tlusty,  J., 1993, “Efficient Simulation Programs for Chatter in Milling,” CIRP Ann., 42, pp. 463–466.
Davies,  M. A., Pratt,  J. R., Dutterer,  B. S., and Burns,  T. J., 2000, “The Stability of Low Immersion Milling,” CIRP Ann., 49, pp. 37–40.
Bayly, V. B., Davies, M. A., Halley, J. E., and Pratt, J. R., 2000, “Stability Analysis of Interrupted Cutting with Finite Time in Cut,” ASME IMECE, Vol. 11, pp. 989–996.
Insperger,  T., and Stepan,  G., 2000, “Stability in the Milling Process,” Periodica Polytechnica Ser. Mech. Eng., 44, pp. 47–57.
Montgomery,  D., and Altintas,  Y., 1993, “Mechanisms of Cutting Force and Surface Generation in Dynamic Milling,” ASME J. Eng. Ind., 115, pp. 245–252.
Altintas,  Y., and Lee,  P., 1998, “Mechanics and Dynamics of Ball End Milling,” ASME J. Manuf. Sci. Eng., 120, pp. 684–692.
Elbestawi,  M. A., and Sagherian,  R., 1991, “Dynamic Modeling for the Prediction of Surface Errors in Milling of Thin-Walled Sections,” Theor. Comput. Fluid Dyn., 25, pp. 215–228.
Budak,  E., Altintas,  Y., and Armarego,  E. J. A., 1996, “Prediction of Milling Force Coefficients from orthogonal Cutting Data,” ASME J. Eng. Ind., 118, pp. 216–223.
Cutpro © Advanced Cutting Process Simulation Software-Milling Module, 1998, Manufacturing Automation Laboratories, Inc.
Campomanes, M., 1998, “Dynamics of Milling Flexible Structures,” M.A.Sc. Thesis, University of British Columbia.
Budak,  E., and Altintas,  Y., 1998, “Analytical Prediction of Chatter Stability Conditions for Multi-Degree of Systems in Milling. Part I: Modelling,” ASME J. Dyn. Syst., Meas., Control, 120, pp. 22–30.
Budak,  E., and Altintas,  Y., 1998, “Analytical Prediction of Chatter Stability Conditions for Multi-Degree of Systems in Milling. Part II: Applications,” ASME J. Dyn. Syst., Meas., Control, 120, pp. 31–36.

Figures

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Milling dynamic model, giving the relative position between the cutting tool and the workpiece at each axial “slice”
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Milling Kinematics model; discretized axial “slice” of the cutter and workpiece system, consisting of an array of (X,Y) points for each of arc, down-milled, and up-milled surfaces
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Updating the discretized arc and finished surface arrays as the cutter moves along the workpiece surface
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Updating the discretized arc surface when entering the workpiece at small radial widths of cut
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Chatter coefficients calculated using predicted uncut chip thickness for (A) stable, (B) borderline stable, and (C) unstable cases
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Predicted 3-D milled surface profile, and predicted and measured cross-section of surface profiles in the axial (Z) direction
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Chatter stability lobes from analytical and time domain models; lumped single point dynamics, half immersion (width of cut: b=9.525 mm), A17075, 4 flute, 30 degree helix
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Chatter stability lobes from analytical frequency domain (Budak and Altintas) and time domain models for a small radial immersion, Y vibrations for stable (A) and unstable (B) depths of cut; lumped single point dynamics. b=2.0 mm, A17075, 4 flute, 30 degree helix
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Chatter stability lobes of interrupted cutting from analytical frequency domain (Budak and Altintas 1617) and time domain (no edge force) models using lumped single point dynamics. Width of cut, b=0.25 mm, A17075, 4 flute, zero helix, single mode at 670 Hz (X&Y)
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Chatter stability lobes of interrupted cutting from time domain: with and without edge force, Y Vibrations for stable (A) and unstable (B) depths of cut with edge forces; lumped single point dynamics. Width of cut, b=0.25 mm,st=0.5 mm, A17075, 4 flute, zero helix, single mode at 670 Hz

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