Hostname: page-component-78c5997874-s2hrs Total loading time: 0 Render date: 2024-11-06T11:16:03.705Z Has data issue: false hasContentIssue false
  • English
  • Français

Anticipation of Stability Limits for Two Degree-of-Freedom Interrupted Milling

Published online by Cambridge University Press:  05 May 2011

B. M. Imani ,
M. H. Sadeghi  and
M. Kazemi
B. M. Imani*
Affiliation:
Department of Mechanical Engineering, Ferdowsi University, Mashhad, Iran
M. H. Sadeghi*
Affiliation:
Department of Mechanical Engineering, Tarbiat Modares University, Tehran, Iran
M. Kazemi*
Affiliation:
Department of Mechanical Engineering, Tarbiat Modares University, Tehran, Iran
*
*Associate Professor
*Associate Professor
**Ph.D. student
Get access

Abstract

Milling is becoming an increasingly universal machining operation for producing parts used in aerospace, automotive, and life science engineering industries. The characteristics common to such parts are a high level of complexity and structural flexibility, both of which usually necessitate using low radial immersion milling operations. Low radial immersion milling operations involve interrupted cutting which induces chatter vibration under certain cutting conditions. The stability behavior of low immersion helical end milling processes is investigated in this paper. Time Finite Element Analysis (TFEA) is suggested for an approximate solution for delayed differential equations encountered during interrupted milling. An improved TFEA is proposed which includes the effects of helix angle variations on cutting force, cutting time and specific cutting force coefficients for a 2 DOF vibratory system. To verify the proposed method, experimental tests have been conducted which prove that the improved TFEA method accurately predicts the stability behavior of low immersion milling.

Keywords

High speed millingLow immersion millingStability lobes.
Type
Articles
Information
Journal of Mechanics , Volume 25 , Issue 1 , March 2009 , pp. 41 - 48
Copyright
Copyright © The Society of Theoretical and Applied Mechanics, R.O.C. 2009

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

References

1.Altintas, Y., Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Vibration, and CNC Design, Cambridge University Press (2000).Google Scholar
2.Sandvick, Coromant, Technical Editorial Dept., Modern Metal Cutting a Practical Handbook, 1st Ed., ISBN 91-972299-0-3 (1994).Google Scholar
3.Ganguli, A., “Chatter Reduction Through Active Vibration Damping,” Ph.D. Dissertation, Universite Libre de Bruxelles (ULB) (2005).Google Scholar
4.Minis, I. and Yanushevsky, R., “A New Theoretical Approach for the Prediction of Machine Tool Chatter in Milling,” Journal of Engineering for Industry, 115, pp. 1–8 (1993).CrossRefGoogle Scholar
5.Altintas, Y. and Budak, E., “Analytical Prediction of Stability Lobes in Milling,” Annals of the CIRP, 44, pp. 357–362 (1995).CrossRefGoogle Scholar
6.Insperger, T., Mann, B. P., Stepan, G. and Bayly, P. V., “Stability of Up-Milling and Down-Milling, Part1: Alternative Analytical Methods,” International Journal of Machine Tools and Manufacture, 43, pp. 25–34 (2003).CrossRefGoogle Scholar
7.Mann, B. P., Bayly, P. V., Davies, M. A. and Halley, J. E., “Limit Cycles, Bifurcations, and Accuracy of the Milling Process,” Journal of Sound and Vibration, 277, pp. 31–48 (2004).CrossRefGoogle Scholar
8.Bayly, P. V., Halley, J. E., Mann, B. P. and Davies, M. A., “Stability of Interrupted Cutting by Temporal Finite Element Analysis,” Transactions of the ASME, Journal of Manufacturing Science and Engineering, 125, pp. 220–225 (2003).CrossRefGoogle Scholar
9.Bayly, P. V., Mann, B. P., Schmitz, T. L., Peters, D. A., Stepan, G. and Insperger, T., “Effects of Radial Immersion and Cutting Direction on Chatter Instability in End-Milling,” Proceedings of ASME Engineering Congress and Exposition, New Orleans, LA, IMECE2002-34116, ASME (2002).Google Scholar
10.Gradisek, J., Govekar, E., Grabec, I., Kalveram, M., Weinert, K., Insperger, T. and Ste'pan, G., “On Stability Prediction for Low Radial Immersion Milling,” Journal of Machine Science and Technology, 9, pp. 117–130 (2005).CrossRefGoogle Scholar