Determination of Chatter-Free Cutting Mode in End Milling

Author(s): Petrakov Y. V.1, Ohrimenko O. A.1, Sapon S. P.2, Sikailo M. O.1, Fedorynenko D. Y.3

Affiliation(s):
1 National Technical University of Ukraine “Igor Sikorsky Kyiv Polytechnic Institute”, 37, Beresteiskyi Ave, 03056, Kyiv, Ukraine;
2 Chernihiv Polytechnic National University, 95, Shevchenka St., 14035, Chernihiv, Ukraine;
3 Tohoku University, 2, Chome-1-1 Katahira, Aoba Ward, Sendai, 980-8577, Miyagi, Japan

*Corresponding Author’s Address: [email protected]

Issue: Volume 11, Issue 2 (2024)

Dates:
Submitted: February 29, 2024
Received in revised form: May 25, 2024
Accepted for publication: June 17, 2024
Available online: July 5, 2024

Citation:
Petrakov Y. V., Ohrimenko O. A., Sapon S. P., Sikailo M. O., Fedorynenko D. Y. (2024). Determination of chatter-free cutting mode in end milling. Journal of Engineering Sciences (Ukraine), Vol. 11(2), pp. A1–A11. https://doi.org/10.21272/jes.2024.11(2).a1

DOI: 10.21272/jes.2024.11(2).a1

Research Area: Machines and Tools

Abstract. Chatter accompanies the cutting process and is the main obstacle to achieving precision and productivity in milling operations. To reduce the amplitude of vibrations, it was proposed to use a stability lobes diagram (SLD) when assigning cutting modes. The machining system in end milling was represented by a two-mass dynamic model in which each mass has two degrees of freedom. The behavior of such a system was described by a structure with two inputs, in-depth and cutting feed, and a delay in positive feedback on these inputs. A new criterion was applied to design the SLD based on an analysis of the location of the machining system Nyquist diagram on the complex plane. The algorithm for designing a stability chart was developed into an application program, a tool for the technologist-programmer when assigning cutting modes. A method for parameter identification necessary for designing the dynamic system “tool – workpiece” was proposed. The effectiveness of the developed method was proven experimentally when the choice of spindle speed during end milling allows one to reduce the roughness parameter Ra from 3.2 µm to 0.64 µm at the same feed rate of 650 mm/min.

Keywords: end milling, simulation, process innovation, stability lobes diagram.

References:

  1. Quintana, G., Ciurana, J. (2011). Chatter in machining processes: A review. International Journal of Machine Tools & Manufacture, Vol. 51, pp. 363–376. http://doi.org/10.1016/j.ijmachtools.2011.01.001
  2. Altintas, Y., Stephan, G., Budak, E., Schmitz, T., Kilic, Z.M. (2020). Chatter stability of machining operations. Journal of Manufacturing Science and Engineering, Vol. 142(11), 110801. http://doi.org/10.1115/1.4047391
  3. Altintas, Y. (2012). Manufacturing Automation. Metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design. Cambridge University Press, Cambridge, UK. https://doi.org/10.1017/CBO9780511843723
  4. Yanez-Valdez, R., Téllez-Galván, J., López-Parra, M., Urbiola-Soto, L. (2022). Dynamic stability of a parallel kinematic machine. Journal of Applied Research and Technology, Vol. 20(1), pp. 1–16. https://doi.org/10.22201/icat.24486736e.2022.20.1.1278
  5. Palpandian, P., Prabhu, R., Satish Babu, S. (2013). Stability lobe diagram for high speed machining processes: Comparison of experimental and analytical methods – A Review. International Journal of Innovative Research in Science, Engineering and Technology, Vol. 2, pp. 747–752. https://api.semanticscholar.org/CorpusID:6443516
  6. Navarro-Devia, J.H., Chen, Y., Dao, D.V., Li, H. (2023). Chatter detection in milling processes – A review on signal processing and condition classification. International Journal of Advanced Manufacturing Technology, Vol. 125, pp. 3943–3980. https://doi.org/10.1007/s00170-023-10969-2
  7. Petrakov, Y., Danylchenko, Y., Sapon, S., Sikailo, M. (2023). Surface relief formation in peripheral end milling. In: Ivanov, V., Trojanowska, J., Pavlenko, I., Rauch, E., Piteľ, J. (eds) Advances in Design, Simulation and Manufacturing VI. DSMIE 2023. Lecture Notes in Mechanical Engineering, pp. 316–326. Springer, Cham. https://doi.org/10.1007/978-3-031-32767-4_30
  8. Sun, Y., Zheng, M., Jiang, S., Zhan, D., Wang, R. (2023), A state-of-the-art review on chatter stability in machining thin walled parts. Machines, Vol. 11, 359. https://doi.org/10.3390/machines11030359
  9. Zhu, L., Liu, C. (2020). Recent progress of chatter prediction, detection and suppression in milling. Mechanical Systems and Signal Processing, Vol. 143, 106840. https://doi.org/10.1016/j.ymssp.2020.106840
  10. Adetoro, O.B., Sim, W.M., Wen, P.H. (2010). An improved prediction of stability lobes using nonlinear thin wall dynamics. Journal of Materials Processing Technology, Vol. 210, pp. 969–979. http://doi.org/:10.1016/j.jmatprotec.2010.02.009
  11. Friedrich, J., Torzewski, J., Verl, A. (2018). Online learning of stability lobe diagrams in milling. Procedia CIRP, Vol. 67, pp. 278–283. http://doi.org/10.1016/j.procir.2017.12.213
  12. Brecher, C., Chavan, P., Epple, A. (2018). Efficient determination of stability lobe diagrams by in-process varying of spindle speed and cutting depth. Journal of Advances in Manufacturing, Vol. 6, pp. 272–279. https://doi.org/10.1007/s40436-018-0225-x
  13. Ren, Y.-Y., Wan, M., Zhang, W.-H., Yang, Y. (2023). A review on methods for obtaining dynamical property parameters of machining processes Mechanical Systems and Signal Processing, Vol. 194, 110280. https://doi.org/10.1016/j.ymssp.2023.110280
  14. Paliwal, V., Ramesh Babu, R. (2020). Prediction of stability lobe diagrams in high-speed milling by operational modal analysis. Procedia Manufacturing, Vol. 48, pp. 283–293. https://doi.org/10.1016/j.promfg.2020.05.049
  15. Yang, Y., Zhang, W.-H., Ma, Y.-C., Wan, M. (2016). Chatter prediction for the peripheral milling of thin-walled workpieces with curved surfaces. International Journal of Machine Tools and Manufacture, Vol. 109, pp. 36–48. https://doi.org/10.1016/j.ijmachtools.2016.07.002
  16. Kashyapi, G., Mohite, S., Belwalkar, N. (2015). Formation of stability lobe diagram (SLD) for chatter free milling on aluminium alloy. Manufacturing Science and Technology, Vol. 3(2), pp. 32–37. http://doi.org/10.13189/mst.2015.030202
  17. Petrakov, Y., Ohrimenko, A., Sikailo, M. (2023). Ensuring the stability of machining when using end mills. Eastern-European Journal of Enterprise Technologies, Vol. 5(1(125)), pp. 73–80. https://doi.org/10.15587/1729-4061.2023.287009
  18. Agarwal, R.P., Berezansky, L., Braverman, E., Domoshnitsky, A. (2012). Introduction to Oscillation Theory. In: Nonoscillation Theory of Functional Differential Equations with Applications. Springer, New York, NY, USA. https://doi.org/10.1007/978-1-4614-3455-9_1
  19. Petrakov, Y., Danylchenko, M. (2022). A time-frequency approach to ensuring stability of machining by turning. Eastern-European Journal of Enterprise Technologies, Vol. 6(2(120)), pp. 85–92. https://doi.org/10.15587/1729-4061.2022.268637
  20. Chen, J., Hu, P., Zhou, H., Yang, J., Xie, J., Jiang, Y., Gao, Z., Zhang, C. (2019). Toward intelligent machine tool. Engineering, Vol. 5(4), pp. 679–690. https://doi.org/10.1016/j.eng.2019.07.018

 

Full Text

© 2024 by the author(s).

This work is licensed under Creative Commons Attribution-Noncommercial 4.0 International License