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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

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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