Research Papers

Identification and Modeling of Process Damping in Milling

[+] Author and Article Information
E. Budak

e-mail: ebudak@sabanciuniv.edu
Manufacturing Research Laboratory,
Sabanci University,
34956 Istanbul, Turkey

Contributed by the Manufacturing Engineering Division of ASME for publication in the Journal of Manufacturing Science and Engineering. Manuscript received September 29, 2010; final manuscript received January 29, 2013; published online March 22, 2013. Assoc. Editor: Patrick Kwon.

J. Manuf. Sci. Eng 135(2), 021001 (Mar 22, 2013) (12 pages) Paper No: MANU-10-1286; doi: 10.1115/1.4023708 History: Received September 29, 2010; Revised January 29, 2013

In this study, a practical identification method for process damping is presented for milling, and the information obtained from identification is used for modeling purposes. In the proposed approach, the process-damping coefficients in x and y directions are identified directly from the experimental stability limits. Then, they are used in identification of the indentation constant through energy balance formulation. The identified indentation constant is further used in modeling of process damping and estimation of stability limit for different cutting conditions and tool geometries. Milling tools with two different types of flank geometries, namely, planar and cylindrical, are considered in this study. The predictions are verified by time-domain simulations and experimental results. It is shown that the presented method can be used for identification and modeling of process damping in milling to determine chatter-free cutting depths at relatively low cutting speeds.

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Fig. 1

Cross section of a helical end mill. (a) End milling system and (b) flank-workpiece interaction.

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Fig. 2

Variation of (a) absolute stability limit and (b) indentation area with speed

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Fig. 3

Experimental stability limits for the example case

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Fig. 4

Variation of indentation volume with several parameters

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Fig. 5

Representative cases for flank-workpiece interaction in milling. (a) Types of flank geometries. (b) Comparison of indentation volume. (c) Representation of indentation area.

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Fig. 6

Effect of vibration amplitude on (a) damping force and (b) average process damping

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Fig. 7

Engagement cases for helical end mill

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Fig. 8

Test setup for the dynamic milling tests

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Fig. 9

Representative cases for chatter identification (test 6). (a) and (b) stable, (c) unstable.

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Fig. 10

Stability limits obtained at the dynamic cutting tests. (a) AL7075. (b) AISI1050. (c) Cylindrical–planar comparison. (d) MRR comparison.

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Fig. 11

Results of the dynamic cutting tests. (a) Average process-damping coefficients in x and y directions. (b) Specific process-damping coefficients.

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Fig. 12

Indentation constant for end milling. (a) Planar flank. (b) Cylindrical flank.

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Fig. 13

Verification of representative cases. (a) Test 2 (AL7075, planar flank). (b) Test 5 (Ti6Al4V, planar flank). (c) Test 7 (AL7075, cylindrical flank).

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Fig. 14

Effect of hone radius and radial depth on process damping. (a) Case 1, effect of hone radius. (b) Case 2, effect of radial depth. (c) Case 2, stability lobe (40% radial).

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Fig. 15

Determination of intersection point. (a) Representation of indentation area. (b) Single segment. (c) Two segment intersection.

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Fig. 16

Representation of (a) cylindrical (radial) flank face. (b) Calculation of flank circle's center.

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Fig. 17

Calculation of indentation area for radial flank geometry




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