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Research Papers

Stability of Milling Operations With Asymmetric Cutter Dynamics in Rotating Coordinates

[+] Author and Article Information
Alptunc Comak

Manufacturing Automation Laboratory,
Department of Mechanical Engineering,
The University of British Columbia,
Vancouver, BC V6T 1Z4, Canada
e-mail: alptunc@alumni.ubc.ca

Orkun Ozsahin

Manufacturing Automation Laboratory,
Department of Mechanical Engineering,
The University of British Columbia,
Vancouver, BC V6T 1Z4, Canada
e-mail: orkunozsahin@gmail.com

Yusuf Altintas

Professor
Fellow ASME
Manufacturing Automation Laboratory,
Department of Mechanical Engineering,
The University of British Columbia,
Vancouver, BC V6T 1Z4, Canada
e-mail: altintas@mech.ubc.ca

1Corresponding author.

Manuscript received August 14, 2015; final manuscript received January 7, 2016; published online March 28, 2016. Assoc. Editor: Tony Schmitz.

J. Manuf. Sci. Eng 138(8), 081004 (Mar 28, 2016) (7 pages) Paper No: MANU-15-1416; doi: 10.1115/1.4032585 History: Received August 14, 2015; Revised January 07, 2016

High-speed machine tools have parts with both stationary and rotating dynamics. While spindle housing, column, and table have stationary dynamics, rotating parts may have both symmetric (i.e., spindle shaft and tool holder) and asymmetric dynamics (i.e., two-fluted end mill) due to uneven geometry in two principal directions. This paper presents a stability model of dynamic milling operations with combined stationary and rotating dynamics. The stationary modes are superposed to two orthogonal directions in rotating frame by considering the time- and speed-dependent, periodic dynamic milling system. The stability of the system is solved in both frequency and semidiscrete time domain. It is shown that the stability pockets differ significantly when the rotating dynamics of the asymmetric tools are considered. The proposed stability model has been experimentally validated in high-speed milling of an aluminum alloy with a two-fluted, asymmetric helical end mill.

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References

Altintas, Y. , 2012, “ Metal Cutting Mechanics,” Machine Tool Vibrations and CNC Design, 2nd ed., Cambridge University Press, Cambridge, UK.
Tobias, S. A. , 1965, Machine-Tool Vibration, Wiley, New York.
Tlusty, J. , and Polacek, M. , 1963, “ The Stability of Machine Tools Against Self-Excited Vibrations in Machining,” ASME Int. Res. Prod. Eng., 1(1), pp. 465–474.
Minis, I. , and Yanushevsky, R. , 1993, “ A New Theoretical Approach for the Prediction of Machine Tool Chatter in Milling,” ASME J. Manuf. Sci. Eng., 115(1), pp. 1–8.
Altintas, Y. , and Budak, E. , 1995, “ Analytical Prediction of Chatter Stability in Milling,” Ann. CIRP, 44(1), pp. 357–362. [CrossRef]
Budak, E. , and Altintas, Y. , 1998, “ Analytical Prediction of Chatter Stability in Milling—Part I: General Formulation,” ASME J. Dyn. Syst., Meas., Control, 120(1), pp. 22–30. [CrossRef]
Insperger, T. , and Stepan, G. , 2004, “ Updated Semi-Discretization Method for Periodic Delay-Differential Equations With Discrete Delay,” Int. J. Numer. Methods Eng., 61(1), pp. 117–141. [CrossRef]
Abele, E. , Altintas, Y. , and Brecher, C. , 2010,“ Machine Tool Spindles,” CIRP Ann. Manuf. Technol., 59(2), pp. 781–802. [CrossRef]
Kivanc, E. B. , and Budak, E. , 2004, “ Structural Modeling of End Mills for Form Error and Stability Analysis,” Int. J. Mach. Tools Manuf., 44(11), pp. 1151–1161. [CrossRef]
Li, C. J. , Ulsoy, A. G. , and Endres, W. J. , 2003, “ The Effect of Flexible-Tool Rotation on Regenerative Instability in Machining,” ASME J. Manuf. Sci. Eng., 125(1), pp. 39–47. [CrossRef]
Eynian, M. , and Altintas, Y. , 2010, “ Analytical Chatter Stability of Milling With Rotating Cutter Dynamics at Process Damping Speeds,” ASME J. Manuf. Sci. Eng., 132(2), p. 0210121. [CrossRef]
Genta, G. , 2005, Dynamics of Rotating Systems, Springer Science & Business Media, New York.
Merdol, S. D. , and Altintas, Y. , 2004, “ Multi-Frequency Solution of Chatter Stability for Low Immersion Milling,” ASME J. Manuf. Sci. Eng., 126(3), pp. 459–466. [CrossRef]

Figures

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Fig. 1

Dynamics and cutting forces in rotating coordinate frame

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Fig. 2

Real and imaginary parts of the measured FRF of the asymmetric end mill in principal rotating coordinates (u, v)

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Fig. 3

Chatter stability diagrams in rotating coordinates for half immersion down-milling operation. Modal parameters are given in Table 1.

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Fig. 4

Experimental verification of the stability for a half immersion down milling with rotating dynamics. Feedrate: 0.2 mm/tooth. Material: Al7050-T7451. Modal and tool parameters are given in Table 1.

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Fig. 5

Simulation and experimental results for the symmetric cutter case

Tables

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