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TECHNICAL PAPERS

Added Stability Lobes in Machining Processes That Exhibit Periodic Time Variation, Part 2: Experimental Validation

[+] Author and Article Information
William T. Corpus

Dept. of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125

William J. Endres

Dept. of Mechanical Engg.–Engg. Mechanics, Michigan Technological University, Houghton, MI 49931-1295

J. Manuf. Sci. Eng 126(3), 475-480 (Sep 07, 2004) (6 pages) doi:10.1115/1.1765136 History: Received October 01, 2002; Revised December 01, 2003; Online September 07, 2004
Copyright © 2004 by ASME
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References

Taylor, S. G., 2000, “Machining Stability With Multi-Dimensional Dynamics and Multi-Tooth, Corner-Radiused Tooling,” M.S. Thesis, Univ. of Michigan, Ann Arbor, Michigan.
Bayly, P. V., Halley, J. E., Davies, M. A., and Pratt, J. R., 2000, “Stability Analysis of Intermittent Machining With Finite Time in Cut,” Proc., Symp. on Machining Processes, ASME IMECE, MED-11 , 989–996.
Insperger,  T., and Stépán,  G., 2000, “Stability of the Milling Process,” Periodica Polytechnica Ser. Mech. Eng.,44, pp. 47–57.
Davies,  M. A., Pratt,  J. R., Dutterer,  B. S., and Burns,  T. J., 2000, “The Stability of Low Radial Immersion Milling,” CIRP Ann., 49, pp. 37–40.
Davies,  M. A., Pratt,  J. R., Dutterer,  B. S., and Burns,  T. J., 2002, “Stability Prediction for Low Radial Immersion Machining,” ASME J. Manuf. Sci. Eng., 124, pp. 217–225.
Corpus, W. T., 2000, “An Added Stability Phenomenon in Machining Processes With Periodic Time Variation,” Ph.D. Thesis, University of Michigan, Ann Arbor, MI.
Budak,  E., and Altintas,  Y., 1998, “Analytical Prediction of Chatter Stability in Milling—Part I: General Formulation,” ASME J. Dyn. Syst., Meas., Control, 120, pp. 22–30.
Endres, W. J., 1996, “The Effect of Cutting Process Models, Process Gain Selection and Process Nonlinearity on Machining Stability Analysis,” Proc., Symp. on Physics of Mach. Processes–III, ASME IMECE, pp. 115–127.
Corpes,  W. T., 2004, “Added Stability Lobes in Machining Processes That Exhibit Periodic Time Variation, Part 1: An Analytical Solution,” ASME J. Manuf. Sci. Eng., 126, pp. 467–474.

Figures

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Displacement power spectra for one-quarter duty cycle tests under (a) traditional chatter (2800 rpm, ωtn=1.52), (b) stable machining in the 0-1/2 peak (3500 rpm, ωtn=1.90), (c) added-lobe chatter (3900 rpm, ωtn=2.12), and (d) stable machining beyond the added lobe (5500 rpm, ωtn=2.98)  
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Experimental stability limit results as compared to those predicted using the model for duty cycles of (a) 1/4, (b) 1/3, and (c) 1/2
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Comparison of simulation results to analytical solutions for continuous machining and the zero-frequency extension of Budak and Altintas’ 6 technique, for duty cycles of (a) 1/8, (b) 1/2, and (c) 7/8
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Zero versus unity overlap for a one-half duty cycle
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Time invariant continuous machining compared to harmonically time-varying continuous machining
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Effect of damping on the 1/2 lobe for a one-half duty cycle
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Zero-damping boundaries as asymptotes for the non-zero damping boundaries—the 1/2 lobe for a one-half duty cycle
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Effect of damping on the 3/2 lobe for a one-half duty cycle

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