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Research Papers

Nonlinear Feed Effect in Machining Chatter Analysis

[+] Author and Article Information
Robert G. Landers

Department of Mechanical and Aerospace Engineering, University of Missouri-Rolla, Rolla, MO 65409-0050landersr@umr.edu

A. Galip Ulsoy

Department of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125ulsoy@umich.edu

J. Manuf. Sci. Eng 130(1), 011017 (Feb 15, 2008) (8 pages) doi:10.1115/1.2783276 History: Received January 22, 2007; Revised July 31, 2007; Published February 15, 2008

Regenerative chatter is a major limitation to the productivity and quality of machining operations due to the excessive rate of tool wear and scrap parts which are produced. Machining chatter analysis techniques examine the stability of the closed-loop model (force process and machine tool-part structure) of the machining operation to determine the stable process parameter space. Almost all chatter analysis techniques assume a linear force process and develop stability lobe diagrams (i.e., plots of the stable and unstable regions in the process parameter space) for a specific feed. It is well known that machining force processes inherently contain a nonlinear relationship between the force and the feed, which is typically described by a power law. In this paper, the linear chatter analysis technique developed by Budak and Altintas is extended to account for the force-feed nonlinearity. The analysis provides insight into the effect feed has on chatter in machining operations. Also, by directly including the force-feed nonlinearity in the chatter analysis, the need to calibrate the force process model at different feeds is alleviated. The analysis is developed for turning and face milling operations and is validated via time domain simulations for both operations and by experiments for a face milling operation. The analyses show excellent agreement with both the time domain simulations and the experiments. Further, several end milling experiments were conducted that illustrate the nonlinear effect feed has on chatter in machining operations.

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Copyright © 2008 by American Society of Mechanical Engineers
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Figures

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Figure 2

Feed-depth stability lobe diagrams for the turning simulation study with Ns=7391rpm. Solid lines are analyses and circles are time domain simulations. Error bars are not shown as they are smaller than the marker size.

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Figure 3

Stability lobe diagrams for the turning simulation study

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Figure 4

Face milling operation schematic (dashed line is previous tooth trajectory)

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Figure 5

Feed-depth stability lobe diagram for the face milling simulation—experimental study with Ns=1519rpm.

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Figure 9

Experimental results for end milling of Ti6A4V with an eight-flute solid carbide end mill using flood coolant (Ns=1750rpm, ff=0.1016mm, w=1.27mm, d=19.05mm). Machining forces for five spindle revolutions are given in the left plot and corresponding power spectral densities are given in the right plot.

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Figure 8

Experimental results for end milling of Ti6A4V with an eight-flute solid carbide end mill using flood coolant (Ns=1750rpm, ff=0.0508mm, w=1.27mm, d=19.05mm). Machining forces for five spindle revolutions are given in the left plot and corresponding power spectral densities are given in the right plot.

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Figure 7

End milling operation schematics (dashed line is previous flute trajectory)

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Figure 1

Turning operation schematic (dashed line is tool trajectory during previous spindle rotation)

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Figure 6

Stability lobe diagrams for the face milling simulation study with: (a) αC=0.933 and αT=0.789; and (b) αC=0.7 and αT=0.7

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