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Research Papers

A New Method for Identification and Modeling of Process Damping in Machining

[+] Author and Article Information
E. Budak

Faculty of Engineering and Natural Sciences, Sabanci University, Istanbul 34956, Turkeyebudak@sabanciuniv.edu

L. T. Tunc

Faculty of Engineering and Natural Sciences, Sabanci University, Istanbul 34956, Turkey

J. Manuf. Sci. Eng. 131(5), 051019 (Oct 01, 2009) (10 pages) doi:10.1115/1.4000170 History: Received December 04, 2008; Revised July 14, 2009; Published October 01, 2009

Although process damping has a strong effect on cutting dynamics and stability, it has been mostly ignored in chatter analysis as there is no practical model for estimation of the damping coefficient and very limited data are available. This is mainly because of the fact that complicated test setups were used in order to measure the damping force in the past. In this study, a practical identification and modeling method for the process damping is presented. In this approach, the process damping is identified directly from the chatter tests using experimental and analytical stability limits. Once the process damping coefficient is identified, it is related to the instantaneous indentation volume by a coefficient which can be used for different cutting conditions and tool geometries. In determining the indentation coefficient, chatter test results, energy, and tool indentation geometry analyses are used. The determined coefficients are then used for the stability limit and process damping prediction in different cases, and verified using time-domain simulations and experimental results. The presented method can be used to determine chatter-free cutting depths under the influence of process damping for increased productivity.

FIGURES IN THIS ARTICLE
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Copyright © 2009 by American Society of Mechanical Engineers
Topics: Damping , Cutting , Stability , Waves
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Figures

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Figure 1

Schematic of SDOF orthogonal cutting and representation of flank-wave contact

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Figure 2

Variation in absolute chatter stability limit with cutting speed

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Figure 3

Representation of instantaneous indentation volume

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Figure 4

Illustration of area of contact: (a) honed edge, (b) sharp edge, and (c) calculation of penetration depth

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Figure 5

Variation in (a) separation angle and (b) total indented area with cutting speed

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Figure 6

(a) Tool holder with the attached mass and (b) experimental setup

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Figure 7

Measured tool vibration at the stability limit

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Figure 8

Examples for stable, LCO, and chatter cases. (a) Resulting surface and measured tool vibration for a marginally stable case, (b) LCO behavior, measured tool vibration and (c) resulting surface and measured tool vibration for pure chatter cases.

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Figure 9

Real part of the FRF of system used in test 5

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Figure 10

Results of the dynamic cutting tests

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Figure 11

Verification of representative test conditions

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Figure 12

Tool displacement for test 5: (a) Time domain simulation and (b) measurement (filtered)

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Figure 13

Effect of various parameters on process damping: (a) Case 1, effect of clearance angle; (b) Case 2, effect of hone radius; and (c) Case 3, effect of vibration frequency.

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