Research Papers

Dynamics of Multipoint Thread Turning—Part I: General Formulation

[+] Author and Article Information
Mohammad R. Khoshdarregi

Intelligent Digital Manufacturing
Laboratory (IDML),
Department of Mechanical Engineering,
University of Manitoba,
Winnipeg, MB R3T 2N2, Canada
e-mail: M.Khoshdarregi@umanitoba.ca

Yusuf Altintas

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

1Corresponding author.

Manuscript received June 28, 2017; final manuscript received November 18, 2017; published online March 9, 2018. Assoc. Editor: Satish Bukkapatnam.

J. Manuf. Sci. Eng 140(6), 061003 (Mar 09, 2018) (11 pages) Paper No: MANU-17-1399; doi: 10.1115/1.4038570 History: Received June 28, 2017; Revised November 18, 2017

This paper formulates the generalized dynamics and stability of thread turning operations with custom multipoint inserts. The closed-loop chip regeneration mechanism is modeled by evaluating the effect of the current vibrations and the vibration marks left from the previous tooth. Using the developed chip discretization method, the dynamic cutting and process damping forces are obtained at each point along the cutting edge by projecting the three-dimensional (3D) vibrations of the tool and workpiece in the direction of local chip thickness. The equation of motion is derived in both physical and modal spaces, and stability is analyzed in frequency domain using Nyquist criterion. An iterative process optimization algorithm has been developed to maximize productivity while respecting machine tool's torque and power limits. Extension of the model to thin-walled workpieces along with the validating experiments on real-scale oil pipes is presented in Part II of this paper.

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Fig. 1

(a) Chip thickness variation due to the current and previous vibrations and (b) chip regeneration mechanism in multipoint thread turning

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Fig. 2

A sample chip element and the defining edge vectors

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Fig. 3

(a) The effect of vibrations on the local chip thickness and (b) dynamic chip area due to the current and previous vibrations

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Fig. 4

(a) Compressed material under the wear land and (b) local process damping forces along the threading tooth

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Fig. 5

A sample three-point V-profile insert used for the simulations

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Fig. 6

(a) Predicted stability chart, ((b)–(e)) the simulated vibrations in threading with the three-point V-profile insert (material: AISI 1045)

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Fig. 7

Nyquist plots with (a) 0.1 Hz and (b) 5 Hz frequency resolution (structural frequencies: 300 Hz and 700 Hz, spindle speed: 1500 rpm, infeed: 3 mm)

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Fig. 8

((a)–(f)) Simulated outputs and ((g)–(j)) the predicted stability charts for the optimized plan (material: AISI 1045, insert: three-point V-profile)



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