Milling is the main method to achieve high speed and high performance metal cutting and its chatter stability, machining accuracy and machining quality have always been a hot research issue. The delayed differential model of a typical two degree of freedom milling system is built, in which the milling force contains static part based on the kinematics of a rigid body and dynamic part based on the regeneration effect. The chatter-free zone of cutting parameters is predicted by the full-discretization method. Under stable cutting conditions, the dynamical cutter tooth path is solved in the frequency domain concerning the interrupted cutting effect. Then the surface location error and the total height of the profile are used to estimate the machining accuracy and machining quality. The experiment basically agrees with theoretical prediction result and it shows that a big depth of cut can be used under resonant spindle speeds, while chatter is more easily to occur in the intermediate area of two neighboring resonant spindle speeds. Chatter can be avoided and the forced vibration can be suppressed by reasonably choosing cutting parameters.
ZHANG Jie
,
LIU Chengying
,
ZHENG Feng
,
YIN Tengfei
. Research on Suppression of the Forced Vibration of the Cutter Based on the Milling Dynamics[J]. Journal of Mechanical Engineering, 2018
, 54(17)
: 94
-99
.
DOI: 10.3901/JME.2018.17.094
[1] ALTINTAS Y. Discrete-time prediction of chatter stability,cutting forces,and surface location errors in flexible milling systems[J]. Journal of Manufacturing Science & Engineering,2012,134(134):061006.
[2] BENAROYA,HAY M. Mechanical vibration:Analysis,uncertainties,and control[M]. 3rd ed. London:Prentice Hall,2010.
[3] BRAVO U,ALTUZARRA O,LACALLE L N L D,et al. Stability limits of milling considering the flexibility of the workpiece and the machine[J]. International Journal of Machine Tools & Manufacture,2005,45(15):1669-1680.
[4] QUINTANA G,CIURANA J. Chatter in machining processes:A review[J]. International Journal of Machine Tools & Manufacture,2011,51(5):363-376.
[5] ALTINTAS Y. Manufacturing automation:Metal cutting mechanics,machine tool vibrations,and CNC design[M]. Cambridge:Cambridge University Press,2012.
[6] ALTINTAS Y, BUDAK E. Analytical prediction of stability lobes in milling[J]. CIRP Annals-Manufacturing Technology,1995,44(1):357-362.
[7] MERDOL S D,ALTINTAS Y. Multi frequency solution of chatter stability for low immersion milling[J]. Journal of Manufacturing Science & Engineering,2004,126(3):459-466.
[8] BAYLY P V,HALLEY J E, MANN B P,et al. Stability of interrupted cutting by temporal finite element analysis[J]. Journal of Manufacturing Science & Engineering,2003,125(2):220-225.
[9] INSPERGER T,STEPEN G. Semi-discretization method for delayed systems[J]. International Journal for Numerical Methods in Engineering,2002,55(5):503-518.
[10] DING Y,ZHU L,ZHANG X,et al. A full-discretization method for prediction of milling stability[J]. International Journal of Machine Tools and Manufacture,2010,50(5):502-509.
[11] SCIMITZ T,ZIEGERT J. Examination of surface location error due to phasing of cutter vibrations[J]. Precision Engineering,1999,23(1):51-62.
[12] MANN B P,YOUNG K A,SCIMITZ T L,et al. Simultaneous stability and surface location error predictions in milling[J]. Journal of Manufacturing Science & Engineering,2005,127(3):446-453.
[13] INSPERGER T,GRADISEK J,KALVERAM M,et al. Machine tool chatter and surface location error in milling processes[J]. Journal of Manufacturing Science & Engineering,2006,128(4):913-920.
[14]
[14] SCIMITZ T,ZIEGERT J. Examination of surface location error due to phasing of cutter vibrations[J]. Precision Engineering,1999,23(1):51-62.
[15] DING Y,ZHANG X J,DING H. Harmonic differential quadrature method for surface location error prediction and machining parameter optimization in milling[J]. Journal of Manufacturing Science and Engineering,2015,137(2):024501.
[16] SCIMITZ T L,DAVIS M A,KENNEDY M D. Tool point frequency response prediction for high-speed machining by RCSA[J]. Journal of Manufacturing Science & Engineering,2001,123(4):700-707.
[17] SZALAI R,INSPERGER T,MANN B P,et al. Nonlinear dynamics of high-speed milling-analyses,numeric,and experiments[J]. Journal of Vibration & Acoustics,2005,127(2):197-203.
