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Research Papers

A Contribution to Improve the Accuracy of Chatter Prediction in Machine Tools Using the Stability Lobe Diagram

[+] Author and Article Information
Raphael Galdino dos Santos

Department of Production Engineering,
School of Engineering at São Carlos,
University of São Paulo,
USP -Av. Trabalhador São-carlense,
400, Pq Arnold Schimidt, Sao Carlos,
SP 13566-590, Brazil;
Department of Product Engineering,
Machine Tools Laboratory,
ROMI Industries S.A.,
Rod. SP304 Km141.5,
Santa Bárbara D'Oeste,
SP 13450-000, Brazil
e-mail: rgsantos@romi.com

Reginaldo Teixeira Coelho

Department of Production Engineering,
School of Engineering at São Carlos,
University of São Paulo,
USP-Av. Trabalhador São-carlense 400,
Pq Arnold Schimidt, Sao Carlos,
SP 13566-590, Brazil
e-mail: rtcoelho@sc.usp.br

Manuscript received June 5, 2013; final manuscript received September 19, 2013; published online January 3, 2014. Assoc. Editor: Tony Schmitz.

J. Manuf. Sci. Eng 136(2), 021005 (Jan 03, 2014) (7 pages) Paper No: MANU-13-1252; doi: 10.1115/1.4025514 History: Received June 05, 2013; Revised September 19, 2013

The chatter phenomenon can severely limit the power available for milling. The stability lobe diagram (SLD) is a very fast and simple method to predict the chatter free zone, allowing the selection of the most adequate spindle speed and depth of cut for higher productivity. However, the data used to calculate the SLD, coming from frequency response functions (FRFs), must be acquired adequately to improve the predictability. FRFs result differently depending on the activation of the spindle electronic control. The present work uses SLDs to investigate these differences and experimental end milling tests to assess the accuracy of SLDs curves. Results indicate that the inclusion of spindle electronic control provides better accuracy in predicting the chatter in milling.

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Figures

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Fig. 1

Machine main structure and an illustration of the spindle with the belt transmission. (a) Machine main structure. (b) Spindle set and belt transmission.

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Fig. 2

Closed-loop control of the CNC spindle, supplied by the manufacturer [29]

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Fig. 3

Set up used to obtain the FRFs. (a) Data acquisition system. (b) Hammer and accelerometer.

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Fig. 4

Setup used for machining tests. (a) Test piece fixed on the machine table. (b) Position of the accelerometers.

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Fig. 5

Magnitude of FRF with spindle free and with M19 activated on the X direction

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Fig. 6

Magnitude of FRF with spindle free and with M19 activated on the Y direction

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Fig. 7

Stability Lobes Diagram for spindle free and with M19 activated. (a) Spindle free (without M19). (b) Spindle with M19 activated.

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Fig. 8

SLD for spindle free and with M19 together with the marks resulting from the end milling tests

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Fig. 9

Vibration levels for 0.4 mm and 1.0 mm depth of cut at 2500 rpm with photos of the surface aspect Fig. 9 (a) 0.4 mm depth of cut (b) 1.0 mm depth of cut

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