Journal articles: 'Chatter Stability'

1

Graham, E., M. Mehrpouya, and S. S. Park. "Robust prediction of chatter stability in milling based on the analytical chatter stability." Journal of Manufacturing Processes 15, no. 4 (October 2013): 508–17. http://dx.doi.org/10.1016/j.jmapro.2013.08.005.

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Shao, Yun Peng, Xi Jing Zhu, Meng Liu, and Zhen Liu. "Stability Analysis of Chatter System on Ultrasonic Honing." Advanced Materials Research 712-715 (June 2013): 1241–47. http://dx.doi.org/10.4028/www.scientific.net/amr.712-715.1241.

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The chatter caused by the inner factors of the machining system in the ultrasonic honing process would seriously affect the surface quality of combustion engine. A dynamical model of ultrasonic honing chatter system was established, which involved with ultrasonic honing mechanism and dynamic honing depth, the relationship between the limit honing width and honing speed was deduced based on the theory of regenerative chatter; the simulation was carried out to obtain the effect of different parameters including stiffness coefficient, damping ratio, spindle speed and reciprocation motion speed on the stability limit curve of the chatter system. It can be concluded that the ultrasonic honing chatter system have better stability with low spindle speed, high stiffness and damping ratio, which providing foundation to eliminate ultrasonic honing system chatter in the precision machining of cylinder liner.

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Huang, Chao, Wen-An Yang, Xulin Cai, Weichao Liu, and YouPeng You. "An Efficient Third-Order Full-Discretization Method for Prediction of Regenerative Chatter Stability in Milling." Shock and Vibration 2020 (June 20, 2020): 1–16. http://dx.doi.org/10.1155/2020/9071451.

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The prediction of regenerative chatter stability has long been recognized as an important issue of concern in the field of machining community because it limits metal removal rate below the machine’s capacity and hence reduces the productivity of the machine. Various full-discretization methods have been designed for predicting regenerative chatter stability. The main problem of such methods is that they can predict the regenerative chatter stability but do not efficiently determine stability lobe diagrams (SLDs). Using third-order Newton interpolation and third-order Hermite interpolation techniques, this study proposes a straightforward and effective third-order full-discretization method (called NI-HI-3rdFDM) to predict the regenerative chatter stability in milling operations. Experimental results using simulation show that the proposed NI-HI-3rdFDM can not only efficiently predict the regenerative chatter stability but also accurately identify the SLD. The comparison results also indicate that the proposed NI-HI-3rdFDM is very much more accurate than that of other existing methods for predicting the regenerative chatter stability in milling operations. A demonstrative experimental verification is provided to illustrate the usage of the proposed NI-HI-3rdFDM to regenerative chatter stability prediction. The feature of accurate computing makes the proposed NI-HI-3rdFDM more adaptable to a dynamic milling scenario, in which a computationally efficient and accurate chatter stability method is required.

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Yu, Ai Bing, Liang Dong, and Yan Lin Wang. "Effect of Wheel Elasticity on Grinding Stability." Applied Mechanics and Materials 37-38 (November 2010): 394–97. http://dx.doi.org/10.4028/www.scientific.net/amm.37-38.394.

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Grinding stability was analyzed concerned with contact deformation and contact stiffness of wheels. Elastic deformations of the grinding wheel were measured with inductance sensors. Dynamic grinding system model was set up. Relation between contact stiffness and chatter growing index was analyzed. Chatter suppression experiments with variable grinding speeds were carried out. When wheel is in contact with a workpiece, contact deformation can occur. The contact stiffness of grinding wheel is a variable. The relation between chatter growing index and contact stiffness is an increasing function. Chatter growing index can be decreased by lowering contact stiffness of wheel. The grinding system stability will be improved with variable grinding speed.

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Cordes, Marcel, Wolfgang Hintze, and Yusuf Altintas. "Chatter stability in robotic milling." Robotics and Computer-Integrated Manufacturing 55 (February 2019): 11–18. http://dx.doi.org/10.1016/j.rcim.2018.07.004.

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Altintas, Y., and J. H. Ko. "Chatter Stability of Plunge Milling." CIRP Annals 55, no. 1 (2006): 361–64. http://dx.doi.org/10.1016/s0007-8506(07)60435-1.

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Lu, Lin, Masahiko Sato, and Hisataka Tanaka. "Experimental Verification of Chatter-Free Ball End Milling Strategy." International Journal of Automation Technology 7, no. 1 (January 5, 2013): 45–51. http://dx.doi.org/10.20965/ijat.2013.p0045.

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Chatter vibration frequently occurs in ball end milling. If the characteristics of the cutting tool system and cutting process are known, chatter stability in ball end milling can be evaluated. Hence, in this paper, a chatter-avoidance strategy based on a regenerative chatter theory is proposed to prevent the occurrence of chatter. This consists of a simulation of chatter stability and cutting condition control. When the characteristics of a vibration system change, this chatter-avoidance strategy cannot cope with it. Therefore, another chatter-avoidance control algorism that changes cutting parameters on a machining center is proposed. This can adapt to the change in the characteristics of the vibration systemduring cutting. The effectiveness of the two chatter-avoidance methods proposed is examined through experiments.

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Jiang, Yong Xiang, San Peng Deng, Yu Ming Qi, and Bing Du. "The Machining Parameters Online Monitoring Method for Stability Prediction." Applied Mechanics and Materials 141 (November 2011): 559–63. http://dx.doi.org/10.4028/www.scientific.net/amm.141.559.

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Unstable grinding due to the regenerative chatter is one of the most critical errors and a serious limitation to achieve good surface quality. The machining accuracy of CNC is greatly depending on online detecting, prediction and control ability of abnormal phenomena in machining such as chatter. Based on the mechanism of regenerative chatter, the dynamic models of cylindrical plunging are established by considering both the rotate speed of workpiece and grinding wheel. The traverse grinding can be assumed as the sum of several stepwise plunging grinding with respect to the grinding contact area. The stability caused by online detecting indexes of grinding parameters was analyzed. Grinding experiments of online chatter detecting were carried out and agreed well with the theoretical results that show good application future for online chatter detecting.

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9

Li, Yu, and Chao Sun. "Chatter Prediction Based on NC Physical Simulation in Machining Ti6Al4V Thin-Walled Components." Applied Mechanics and Materials 395-396 (September 2013): 1008–14. http://dx.doi.org/10.4028/www.scientific.net/amm.395-396.1008.

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Chatter has been a problem in CNC machining process especially during machining thin-walled components with low stiffness. For accurately predicting chatter stability in machining Ti6Al4V thin-walled components, this paper establishes a chatter prediction method considering of cutting parameters and tool path. The fast chatter prediction method for thin-walled components is based on physical simulation software. Cutting parameters and tool path is achieved through the chatter stability lobes test and finite element simulation. Machining process is simulated by the physical simulation software using generated NC code. This proposed method transforms the NC physical simulation toward the practical methodology for the stability prediction over the multi-pocket structure milling.

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10

He, Feng-Xia, Li Dai, Qisen Chen, Yu Liu, and Zhong Luo. "Three-dimensional stability analysis of robotic machining process." Industrial Robot: the international journal of robotics research and application 47, no. 1 (September 19, 2019): 82–89. http://dx.doi.org/10.1108/ir-02-2019-0036.

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Purpose Since robot’s structural stiffness is usually less than 1 N/µm, mode coupling chatter occurs frequently during robotic milling process, and chatter frequency is close to the natural frequency of the robot itself. Chatter not only affects the surface quality but also damages the robot and reduces the positioning accuracy. Therefore, it is necessary to predict chatter in robotic machining process. Design/methodology/approach A three-dimensional dynamic model for robot’s spatial milling plane is established, and a corresponding stability criterion is obtained. First, the cutting force in milling plane is transformed into the coordinate system of the robot principal stiffness direction based on homogeneous transformation matrix. Then the three-dimensional stability criterion under milling process can be obtained by using system stability analysis. Furthermore, the circle diagram of mode coupling chatter stability is drawn. Each feeding direction’s stability under the two processing forms, referred as spindle vertical milling and spindle horizontal milling, is analyzed. Findings The experimental results verify that the three-dimensional stability criterion can avoid chatter by selecting machining feed direction in stable area. Originality/value This paper established a three-dimensional dynamic model in robot’s spatial milling plane and proposed a three-dimensional stability criterion according to the Routh criterion. The work is also expected to be an efficient tool in the development of robotic milling technology.

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11

Chen, Y., S. Liu, T. Shi, S. Yang, and G. Liao. "Stability analysis of the rolling process and regenerative chatter on 2030 tandem mills." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 216, no. 12 (December 1, 2002): 1225–35. http://dx.doi.org/10.1243/095440602321029463.

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Chatter in the rolling stack of high-velocity tandem mills and temper mills is a widespread problem and affects the quality of the finished product and the productivity of the rolling mill. One factor that clearly plays an important role in causing mill vibration is the inherent gap between the roll chocks and mill housings. In order to control chatter in cold rolling operations, a much deeper understanding of the basic mechanics of the problem is required. Therefore, this paper proposes a rolled piece vibration model for comprehending instability of the strip due to the variation of the friction coefficient in the roll bite. Subsequently, owing to the time delay effect of the chatter marks between the immediate stands, a regenerative chatter model is developed and stability analysis of the regenerative chatter model due to negative damping is presented. Finally, for a more detailed understanding of the regenerative chatter phenomena, a simulator is developed and industrial investigations are carried out in practice. It follows from the numerical simulations and industrial investigations that regenerative chatter is a more serious vibration phenomenon than simple chatter.

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12

Long, Hua, Yong Xin Luo, Xiao Long Shen, and Bei Chen Zhao. "Research on Efficiency and Stability of Computer Numerical Control Lathe." Applied Mechanics and Materials 120 (October 2011): 108–13. http://dx.doi.org/10.4028/www.scientific.net/amm.120.108.

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In order to study the highly efficient and stable cutting of computer numerical control lathe (CNC lathe), this paper established a dynamics model of chatter turning system on tool side, and analyzed the influences of the chatter stable lobes about the CNC lathe system’s overlap coefficient, cutting rigidity coefficient in unit width, main vibration system’s damping ratio, and observed the chatter effects about the chatter stable lobes in different regions by experimental methods. Research shows that the choice of the cutting speed in the stable regions can significantly increase the cutting width, and improve the efficiency of cutting.

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13

Ma, Hai Long, Ai Jun Tang, and Qing Kui Chen. "Stability Prediction Model for Milling Process." Advanced Materials Research 490-495 (March 2012): 2829–33. http://dx.doi.org/10.4028/www.scientific.net/amr.490-495.2829.

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In the process of milling thin-walled plate, chatter is one of the major limitations on productivity and part quality even for high speed and high precision milling machines. Therefore, it is necessary to avoid chatter with a suitable choice of cutting condition. This paper studies the dynamic stability models of milling the thin-walled plate by analyzing the geometrical relationship of cutting, and derives the mathematic expressions in theory. Moreover, this paper develops a three-dimensional lobes diagram of the spindle speed, the axial depth and the radial depth. Through the three-dimensional lobes, it is possible to choose the appropriate cutting parameters according to the dynamic behavior of the chatter system.

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14

Ren, Yong Sheng, Ji Shuang Tian, Yu Huan Zhang, and Jing Min Ma. "Prediction of Regeneration Chatter Stability of Composite Boring Bar." Solid State Phenomena 295 (August 2019): 73–83. http://dx.doi.org/10.4028/www.scientific.net/ssp.295.73.

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The deep holes cutting process by metal boring bar is usually limited due to the development of chatter vibration. This is because metal boring bar has not only low bending stiffness but also low structural damping. A chatter stability prediction of composite boring bar under regenerative cutting force is presented. Based on the theory of Euler-Bernoulli beam, the regenerative chatter dynamic model of composite boring bar is proposed, and the solution formula of the limited cutting depth and corresponding spindle speed is given. The dynamic stability lobes of the composite boring bar are obtained by numerical calculation. The results indicate that composite boring bar exhibits efficient chatter stability than metal boring bar. Chatter stability is closely related to fiber ply angle. It is demonstrated that when ply angle is 0o, carbon/ epoxy reaches its critical cutting depth, and for graphite/ epoxy boring bar about 25o of ply angle gives its critical cutting depth, It is also demonstrated that stability boundary decreases as the ratio length and diameter increases. Finally, the prediction results of stability are compared with those from the dynamic stiffness and time-domain response, agreement is found.

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15

Zhang, Li Ying, Jin Hui Li, and Jun Tao Hu. "The Motional Stability Analysis and Optimal Design of Built-In Chatter Suppression Boring Bar." Advanced Materials Research 694-697 (May 2013): 430–35. http://dx.doi.org/10.4028/www.scientific.net/amr.694-697.430.

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On the basis of the Mechanics and Kinematics analysis of built-in chatter suppression boring bar, the research analyzes the motional stability of built-in chatter suppression boring bar, and uses SIMS vibration absorbers for chatter suppression theory to design the characteristic parameters of vibration absorber; then with MATLAB optimized to get structural material parameters of vibration absorber; finally conduct harmonic response analysis to built two-dimensional model of built-in chatter suppression boring bar by ANSYS, compare and optimize the results to guide the development of built-in chatter suppression boring bar.

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16

Zhang, Xiao Guang, Qiu Ping Ren, and Hong Du. "The Study of Stability of Time-Delay Systems in Milling." Applied Mechanics and Materials 633-634 (September 2014): 751–54. http://dx.doi.org/10.4028/www.scientific.net/amm.633-634.751.

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The effect on the stability of the analysis of time lag effect of the milling system，Reveals the root cause of the milling type regenerative chatter occurs，Milling type regenerative chatter is derived from the time-delay feedback within the system，Application of routh criterion and Fourier analysis of chatter in milling system before and after the change of rigidity and damping system, it is concluded that the limit cutting depth.

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17

Ismail, F., and A. Bastami. "Improving Stability of Slender End Mills Against Chatter." Journal of Engineering for Industry 108, no. 4 (November 1, 1986): 264–68. http://dx.doi.org/10.1115/1.3187076.

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The strongest mechanisms that contribute to machining chatter are regeneration and mode coupling. Special designs of milling cutters have evolved with the aim to increase stability against chatter by disturbing the regeneration mechanism. However, in the case of slender end mills, the mode coupling remains most active. In this work, a new approach is presented where a design change of the cutter is suggested to weaken the mode coupling mechanism. Time domain simulation of the development of chatter showed that using this approach significant increase in stability could be achieved. Cutting tests of aluminum with the modified end mills confirmed simulation results.

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18

LIU, EYSION A., SIMON HO, MITCHEL WEHRLY, and WILLIAM F. RESH. "FEA APPLICATIONS IN MILLING CHATTER STABILITY ANALYSIS." Journal of Advanced Manufacturing Systems 04, no. 01 (June 2005): 53–67. http://dx.doi.org/10.1142/s0219686705000576.

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Regenerative chatter is a major hurdle to the productivity and quality of machining operations. This is because of the undesirable surface finish, excessive tool wear and deteriorated dimensional accuracy. Machining chatter analysis techniques examine the stability of a closed-loop model of machining forces and tool-workpiece system. This model is based on mathematical manipulations of machining forces and the dynamic responses of machining tooling. Almost all techniques derive the dynamic responses from physical test. In this paper, a novel approach of milling chatter stability analysis is introduced by using FEA applications to obtain the dynamic responses of the machine tool. The accuracy of this methodology is validated by machine shop tests.

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19

Luo, Yong Xin, Xiao Long Shen, Hua Long, and Lai Xi Zhang. "Research on Milling Stability Using CNC Small Size Tool." Advanced Materials Research 199-200 (February 2011): 1993–98. http://dx.doi.org/10.4028/www.scientific.net/amr.199-200.1993.

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In a larger-power CNC milling machine, the milling stability of CNC small size tool which is less than φ 25 diameters is restricted under a certain degree. Authors studied CNC milling chatter stability by the experiment and simulation; they had researched those influences of tool’s diameter, suspended length and craft of manufacturing system on chatter stability domain. Researches show that the larger diameter and shorter suspended length of the tool can improve the stability of milling, and also can improve critical axial cutting depth. The lobes of chatter stability domain can forecast effectively critical axial cutting depth and relevant to milling speed, can better mining machine cutting potential.

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20

Petrakov, Yuriy, Mariia Danylchenko, and Andrii Petryshyn. "Prediction of chatter stability in turning." Eastern-European Journal of Enterprise Technologies 5, no. 1 (101) (October 1, 2019): 58–64. http://dx.doi.org/10.15587/1729-4061.2019.177291.

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21

Kebdani, S., A. Sahli, O. Rahmani, D. Boutchicha, and A. Belarbi. "Analysis of Chatter Stability in Facing." Journal of Applied Sciences 8, no. 11 (May 15, 2008): 2050–58. http://dx.doi.org/10.3923/jas.2008.2050.2058.

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Yoon, Moon-Chul, and Young-Guk Kim. "Chatter stability boundary analysis using RBNN." Journal of Materials Processing Technology 184, no. 1-3 (April 2007): 251–56. http://dx.doi.org/10.1016/j.jmatprotec.2006.11.097.

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23

Gupta, Pankaj, and Bhagat Singh. "Analyzing chatter vibration during turning on computer numerical control lathe using ensemble local mean decomposition and probabilistic approach." Noise & Vibration Worldwide 52, no. 6 (March 12, 2021): 168–80. http://dx.doi.org/10.1177/0957456521999871.

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Chatter vibration is an undesired and indispensable phenomenon in turning operation, which cannot be completely avoided. However, it can be suppressed by early identification and with the proper choice of input turning parameters. The key issue of chatter detection is to process the acquired signals and extract the features pertaining to it. In the present work, a methodology has been proposed for exploring tool chatter features in the incipient stage during turning on lathe. Chatter signals generated during the turning of Al 6061-T6 have been acquired using a microphone. A stability lobe diagram has been plotted to access the stability regime. Further, in order to study the effect of feed rate on stability, the recorded signals have been processed using a local mean decomposition signal processing technique, followed by the selection of dominating product functions using the Fourier transform. The decomposed signals have been used to evaluate the new output parameter, that is, chatter index. Further, the Nakagami probability distribution has been used to ascertain stability region (threshold). From the experimental validation, it has been inferred that cutting combinations obtained from the Nakagami probability distribution are significant and capable of limiting chatter vibrations. The present methodology will serve as guidelines to the researchers and machinist for the identification of tool chatter in the incipient stage, explore its severity, and finally suppress it with the proper selection of input turning parameters.

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Yuhuan, Zhang, Ren Yongsheng, Tian jishuang, and Ma jingmin. "Chatter stability of the constrained layer damping composite boring bar in cutting process." Journal of Vibration and Control 25, no. 16 (June 4, 2019): 2204–14. http://dx.doi.org/10.1177/1077546319852240.

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Traditional boring bars are generally made up of isotropic metallic materials and exhibit extremely poor chatter suppression ability. For enhancing the chatter stability, using anisotropic composite materials in the preparation of boring bars proves to be an effective method so as to enhance the boring bar’s natural frequency and damping. Additionally, the addition of constrained layer damping (CLD) technology on the composite boring bar can further improve the damping performance. This study aims to develop a theoretical analysis model for the prediction of the chatter stability of the CLD composite boring bar and explore the effectiveness and practicability of the CLD technology in suppressing the chatter of composite boring bar. Based on Euler–Bernoulli beam theory and the complex stiffness method of CLD, the structural dynamic model of the CLD composite boring bar was derived, and some structural parameters of the bar mainly including the ply angle of the composite material, the thicknesses of both damping layer, and constrained layer were also optimized. By combining the linear model of cutting force with a regenerative delay effect and the established dynamic model, the chatter analysis model of the CLD composite boring bar was constructed and the lobe diagram of the chatter stability of the cutting system was plotted by means of frequency domain method. The effects of the ply angle of the composite boring bar, the thicknesses of damping layer, and constrained layer on the chatter stability were examined. By performing time integral of the delay equation of motion, the time-domain response curves of the cutting system are obtained. The chatter stability prediction results based on the lobe diagram fit well with the prediction results on the basis of dynamic stiffness calculation and time-domain numerical integral results.

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Sasahara, Hiroyuki, and Yoshihisa Naito. "Prediction and Avoidance of Chatter in Milling of Thin-Walled Structure." Key Engineering Materials 407-408 (February 2009): 404–7. http://dx.doi.org/10.4028/www.scientific.net/kem.407-408.404.

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An objective of this study is to develop a new method for the prediction and the avoidance of chatter vibration in milling operation of thin-walled structure by using 3D-CAD and CAE approach. Also, a new identification method for the modal parameters of a vibration system by analyzing radiated sound pressure from vibrated workpiece accelerated by an impulse force is proposed. Then chatter stability lobes are predicted using those modal parameters. Stiffness and modal shapes of the workpiece were obtained using commercial finite element method (FEM) code, and the model was made by 3D-CAD. The damping ratio, which cannot be determined through FEM analysis, was identified from the relationship between the sound pressure radiated from the workpiece and the impulse force. Chatter stability limit was analyzed with the modal parameters obtained through these procedures, and compared with the cutting experiment on the chatter stability limit. The experimental and predicted stability limits are in good agreement. The proposed procedure will help to set the cutting conditions to avoid the chatter.

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Zhang, Nan, Yaoyao Shi, Zhen Chen, Hongxia Chen, Jia Liu, and Pan Zhao. "Chatter reliability prediction of side milling blisk." Xibei Gongye Daxue Xuebao/Journal of Northwestern Polytechnical University 39, no. 1 (February 2021): 111–18. http://dx.doi.org/10.1051/jnwpu/20213910111.

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During the blisk side milling, the blade is thin and the tool suspension length is large, which is easy to occur milling system chatter. The wavy surface left by chatter has great effect on the surface roughness and service performance of the aero-engine blisk. To accurately predict the stability of the blisk side milling, the influence of random variables on the machining stability was considered. In this paper, the chatter reliability model of the blisk side milling system was established using the first-order second-moment method. The model takes structural parameters and spindle speed as random variables and chatter frequency as intermediate variables. The chatter reliability model was used to draw the reliability lobe diagram, which can be used to divide the machining reliability area. The effectiveness of this method was verified by experiments and compared with Monte Carlo method. The validation results showed that the reliability lobe diagram can be used to determine the stability probability prediction of blisk side milling and can replace the traditional stability lobe diagram.

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Cui, Li, and Yin Su. "Chatter Stability Prediction Method of the Spindle-Tool Holder-Tool System with Interface Contact Characteristics." Mathematical Problems in Engineering 2020 (December 5, 2020): 1–15. http://dx.doi.org/10.1155/2020/7121328.

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To predict chatter stability and suppress chatter vibration, a chatter stability prediction method for the spindle-tool holder-tool system with interface contact characteristics is constructed. A five-DOF model is constructed to determine the spindle-bearing interface dynamic contact stiffness considering the coupling effect of spindle and bearing. A fractal multiscale tool holder-spindle interface dynamic stiffness model is proposed considering time-varying cutting force. The fractal dimensions and cutting force coefficient parameters are identified from the power spectrum experiments and cutting force tests. The cutting force is solved according to the milling stability model. Dynamic model of the spindle-tool holder-tool system is found by the finite element method. Based on extended Floquet theory, chatter stability of the spindle system is studied. Effect of interface parameters, radial cutting depth, and feed rate on milling stability is researched. Milling force tests and milling stability tests are performed in order to verify the reliability of the method. Results find that the increase of front bearing preload and spindle-tool holder’s interference fit are effective to improve the milling stability. The optimal feed rate and the critical radial cutting depth are found. The model proposed in this paper can be used as an instruction for predicting and suppressing the chatter vibration and optimizing cutting parameters and also is helpful for designing the spindle-tool holder-tool system.

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Motallebia, A., A. Doniavi, and Y. Sahebi. "An Analysis and Modeling of the Dynamic Stability of the Cutting Process Against Self-Excited Vibration." Mechanics and Mechanical Engineering 23, no. 1 (July 10, 2019): 28–35. http://dx.doi.org/10.2478/mme-2019-0005.

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Abstract Chatter is a self-excited vibration that depends on several parameters such as the dynamic characteristics of a machine tool structure, the material of work piece, the material removal rate, and the geometry of tools. Chatter has an undesirable effect on dimensional accuracy, smoothness of work piece surface, lifetime of tools and machine tools. Thus, it is useful to understand this phenomenon in order to improve the economic aspect of machining. In the present article, firstly, the theoretical study and mathematical modeling of chatter in the cutting process were carried out. Then, by performing modal testing on a milling machine and drawing chatter stability diagrams, we determined the stability regions of the machine tool operation and recognized the parameter that had the most important effect on chatter.

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Minis, I., and A. Tembo. "Experimental Verification of a Stability Theory for Periodic Cutting Operations." Journal of Engineering for Industry 115, no. 1 (February 1, 1993): 9–14. http://dx.doi.org/10.1115/1.2901645.

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The stability of periodic cutting operations, the dynamics of which are described by linear differential-difference equations with periodic coefficients, is studied. A new stability theory that uses parametric transfer functions and Fourier analysis to obtain the characteristic equation of such systems is experimentally verified. The theory is applied to single-point turning of a compliant work piece with two degrees-of-freedom. The theoretical predictions of both the critical depth of cut for chatter-free turning and the corresponding chatter frequency were found to be in good agreement with the measurements obtained from actual chatter tests under various surface speeds.

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Li, Jin Hua, Yong Xian Liu, Hua Long Xie, Wei Wang, and Bao Zhong Feng. "Research on Mechanism and Model of Cutting Chatter Based on the Cutting Parameters." Advanced Materials Research 479-481 (February 2012): 217–20. http://dx.doi.org/10.4028/www.scientific.net/amr.479-481.217.

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According to the kinematics and dynamic theory, the regenerative cutting chatter is derived on the math and simplified within the probable range. The correlation is gained between the cutting depth limit and the spindle speed about the regenerative chatter. In Matlab, the mathematical modal is simulated based on the modal parameters, cutting parameters and cutting-force coefficients. The stability lobes are drawn in the diagram, the stability zone lies under the curve and avoid the occurrence of cutting chatter.

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Bayly, Philip V., Sandra A. Metzler, Adam J. Schaut, and Keith A. Young. "Theory of Torsional Chatter in Twist Drills: Model, Stability Analysis and Composition to Test." Journal of Manufacturing Science and Engineering 123, no. 4 (November 1, 2000): 552–61. http://dx.doi.org/10.1115/1.1381399.

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The mechanism of torsional chatter in drilling differs qualitatively and quantitatively from other types of chatter. In this paper we show that torsional chatter can be explained by the torsional-axial coupling inherent in a twisted beam; the beam “untwists” and extends in response to an increase in cutting torque. Based on a model of this mechanism, predictions of stability boundaries and chatter frequencies are derived by frequency domain analysis, and confirmed by numerical simulation and experimental tests. The effect of the torsional-axial coupling is opposite that of traditional cutting in that an increase in cutting forces leads to axial extension and greater chip load. Because of this sign difference, the limiting depth of cut is governed by the positive real part of the frequency response function, which explains the unexpected fact that torsional chatter occurs below the natural frequency of the tool.

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Tang, A. J., and Zhan Qiang Liu. "Effect of Helix Angle and Normal Rake Angle on Stability in End Milling." Advanced Materials Research 69-70 (May 2009): 394–98. http://dx.doi.org/10.4028/www.scientific.net/amr.69-70.394.

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Chatter phenomenon often occurs during end milling of metal-cutting and becomes a common limitation to achieve high productivity and part quality. This paper studies the relationship expression between the parameters of oblique cutting and milling coefficients by analyzing the geometrical relationship of oblique cutting, and derives the mathematic expressions in theory between the cutter parameters and chatter. For the purpose of chatter avoidance, this paper studies the effect of helix angle and normal rake angle on milling stability under the condition of the same milling parameters, and plots the three-dimensional stability lobes of the spindle speed, axial and radial depths. It can be found that the milling stability is increased with the increment of helix angle and normal rake angle. Through the three-dimensional lobe, it is possible to choose the appropriate cutter parameters to reduce and avoid the chatter.

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Budak, E., and Y. Altintas¸. "Analytical Prediction of Chatter Stability in Milling—Part I: General Formulation." Journal of Dynamic Systems, Measurement, and Control 120, no. 1 (March 1, 1998): 22–30. http://dx.doi.org/10.1115/1.2801317.

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A new analytical method of chatter stability prediction in milling is presented. A general formulation for the dynamic milling system is developed by modeling the cutter and workpiece as multi-degree-of-freedom structures. The dynamic interaction between the milling cutter and workpiece is modeled considering the varying dynamics in the axial direction. The dynamic milling forces are governed by a system of periodic differential equations with delay whose stability analysis leads to an analytical relation for chatter stability limit in milling. The model can be used to determine the chatter free axial and radial depth of cuts without resorting to time domain simulations.

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Xie, Jin Hua, Rui Huo, Ying Gao, and Yan Feng Guan. "The Analysis and Simulation of Stability on Cutting Chatter System Based on Matlab." Advanced Materials Research 569 (September 2012): 615–19. http://dx.doi.org/10.4028/www.scientific.net/amr.569.615.

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Cutting chatter is a complexly phenomena of dynamic instability in mechanical processing process, scholars have done lots of researchs about it[1]. This paper has deduced the kinematics differential equation and limit cutting width of regenerative cutting chatter, analyzed the influence of dynamic parameters on the stability of cutting system. Simulation of time signal on cutting chatter is modeled through Matlab Use mathematical method[2] to obtain numerical value of limit cutting width.

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Quintana, Guillem, Joaquim de Ciurana, Daniel Teixidor, and I. Ferrer. "Experimental Introduction to Forced and Self-Excited Vibrations in Milling Processes and Identification of Stability Lobes Diagrams." Materials Science Forum 692 (July 2011): 24–32. http://dx.doi.org/10.4028/www.scientific.net/msf.692.24.

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In milling operations, cutting edge impacts due to the interaction between the cutter and the workpiece excite vibrations. It is possible to distinguish between free, forced and self-excited vibrations. Chatter is a self-excited vibration that can occur in machining processes, and is considered to be a common limitation of productivity and quality. Stability lobes diagrams (SLDs) show the frontier between chatter-free milling operations, i.e. stable dominated by forced vibrations, and operations with chatter, i.e. unstable. These diagrams are usually obtained from impact hammer testing. However, this method requires trained personnel with advanced knowledge and it is not easily applied in engineering studies or operator training. This paper presents an experimental method that allows engineering students and operators-in-training to observe the chatter phenomenon and to distinguish between forced and chatter vibrations and identify process stability diagrams.

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Alan, Salih, Erhan Budak, and H. Nevzat Özgüven. "Analytical Prediction of Part Dynamics for Machining Stability Analysis." International Journal of Automation Technology 4, no. 3 (May 5, 2010): 259–67. http://dx.doi.org/10.20965/ijat.2010.p0259.

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An analytical procedure is developed to predict workpiece dynamics in a complete machining cycle in order to obtain frequency response functions (FRF), which are needed in chatter stability analyses. For this purpose, a structural modification method that is an efficient tool for updating FRFs is used. The mass removed by machining is considered to be a structural modification in order to determine the FRFs at different stages of the process. The method is implemented in a computer code and demonstrated on different geometries. The predictions are compared and verified by FEA. Predicted FRFs are used in chatter stability analyses, and the effect of part dynamics on stability is studied. Different cutting strategies are compared for increased chatter-free material removal rates considering part dynamics.

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Zhang, Chunjin, Yongsheng Ren, Shujuan Ji, and Jinfeng Zhang. "Analysis of the Vibration and Chatter Stability of a Tapered Composite Boring Bar." Shock and Vibration 2020 (June 27, 2020): 1–11. http://dx.doi.org/10.1155/2020/4190806.

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As metal boring bars have low dynamic stiffness, chatter is easily induced during the boring process. Therefore, improvement of the chatter stability is an open problem that requires further study. Though researchers proved that the composite materials suitable for making tapered boring bars can further improve the dynamic stiffness to meet the need of high-speed boring, existing research studies did not study the dynamic characteristics of the tapered composite boring bar comprehensively. In particular, no research has been done about the natural frequency and chatter stability of the composite boring bar under various taper ratios. Therefore, in this paper, a model of a tapered composite boring bar is established based on the Adomian modified decomposition method (AMDM). Second, this paper verifies the effectiveness of the AMDM by using the ANSYS software. Moreover, this paper studies the natural frequency of the boring bar model under various situations. Third, we verify the convergence of chatter stability of the boring bar model. Finally, the chatter stability of the tapered composite boring bar is analyzed comprehensively. The results show that the natural frequency and the chatter stability of the tapered model can be improved by choosing appropriate taper ratio, ply angle, stacking sequences, L/D ratio, T/D ratio, and the carbon composite. The results are helpful for the design of high-quality tapered composite boring bars matching the need of high speed cutting. In particular, these results can provide guidelines for adjusting the cutting speed in CNC boring and can further improve the surface finish of the machined workpieces.

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Hsiao, Te Ching, Chao Yu Huang, and Jiunn Jyh Junz Wang. "Analysis on Milling Stability Performed under the Conditions of Positive and Negative Process Stiffness." Advanced Materials Research 690-693 (May 2013): 2408–21. http://dx.doi.org/10.4028/www.scientific.net/amr.690-693.2408.

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This paper aims at discussing chatter characteristics performed by a one-dimensional milling system having positive process stiffness and negative process stiffness. In this study, a dynamic model of the milling system is established first. An analytical form showing the critical chatter conditions including axial depth of cut, chatter frequency, critical spindle speed, etc. is formed. The analysis of process function shows that positive process stiffness occurs under most cutting conditions. However, process stiffness becomes negative when a one-dimensional milling system carries out low radial depth of cut in the direction of the feed (down milling) or semi-groove milling in the direction against the feed (up milling). Further analysis is made to explore chatter characteristics performed by the milling systems with positive process stiffness and negative process stiffness respectively. Finally, the prediction equation calculating critical chatter conditions of these two types of milling system, the range of rotation speed with high cutting stability and the range of rotation speed with low cutting stability is proposed.

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Hao, Daxian, Wei Wang, Zhaoheng Liu, and Chao Yun. "Experimental study of stability prediction for high-speed robotic milling of aluminum." Journal of Vibration and Control 26, no. 7-8 (October 29, 2019): 387–98. http://dx.doi.org/10.1177/1077546319880376.

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It has been fully demonstrated that the regenerative chatter theory is applicable for predicting chatter-free milling parameters for computer numerical control machine tools, but researchers are still arguing whether it is effective for robotic milling processes. The main reason is that the robot’s modes greatly shift, depending on its varying dynamic parameters and joint configurations. More experimental investigations are required to study and better understand the mechanism of vibration in robotic machining. The present paper is focusing on finding experimental support for chatter-free prediction in robot high-speed milling by the regenerative chatter theory. Modal tests are first conducted on a milling robot and used to predict stability lobes by zeroth order approximation. A number of high-speed slotting tests are then carried out to verify the prediction results. Thus, the regenerative chatter theory is proved to be also applicable to robotic high-speed milling. Furthermore, low-frequency modes of the robot structure are investigated by more modal experiments involving a laser tracker and a displacement sensor. The low-frequency modes are identified as the main part of the prediction error of the zeroth order approximation method, which could also be dominant in low-speed robotic milling processes. In addition, robots are different from computer numerical control machines in terms of stiffness, trajectory following error, forced vibration, and motion coupling. These long-period trend terms have to be carefully taken into account in the regenerative chatter theory for robotic high-speed milling.

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Mehdi, K., J. F. Rigal, and D. Play. "Dynamic Behavior of a Thin-Walled Cylindrical Workpiece During the Turning Process, Part 1: Cutting Process Simulation." Journal of Manufacturing Science and Engineering 124, no. 3 (July 11, 2002): 562–68. http://dx.doi.org/10.1115/1.1431260.

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From a practical point of view, in machining applications, chatter vibration constitutes a major problem during the cutting process. It is becoming increasingly difficult to suppress chatter during cutting at high speeds. Many investigators have regarded chatter vibrations as a “natural” phenomenon during the cutting process and a part of the process itself. In classical machining operations with thick-walled workpieces chatter vibrations occur when the cutting depth exceeds stability limits dependent on the machine tool. On the other hand, in the case of thin-walled cylindrical workpieces, chatter vibration problems are not so simple to formulate. The main purpose of this study is to qualify the dynamic behavior of a thin-walled workpiece during the turning process. It contains two parts: the cutting process simulation and the definition of experimental stability criteria. In the first part, a numerical model, which simulates the turning process of thin-walled cylindrical workpieces, is proposed. This model also permits obtaining workpiece responses to excitation generated by cutting forces. Finally, the stability of the process is discussed.

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Kumar, Shailendra, and Bhagat Singh. "Ascertaining of chatter stability using wavelet denoising and artificial neural network." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 233, no. 1 (February 8, 2018): 39–62. http://dx.doi.org/10.1177/0954406218756440.

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In modern machining industries, tool chatter detection and suppression along with maximized metal removal rate is a challenging task. Inexpedient vibration between cutting tool and work piece promotes unstable cutting. This results in enhanced detritions of tool and poor surface finish along with unpredictable metal removal rate. In the present work, effect of machining parameters such as depth of cut ( d), feed rate ( f) and spindle speed ( N) on chatter severity and metal removal rate have been ascertained experimentally. Experimentally recorded raw chatter signals have been denoised using wavelet transform. An artificial neural network model based on feed forward back propagation network has been proposed for predicting stable cutting zone and metal removal rate in turning process. It has been deduced that Tangent Sigmoid activation function in an artificial neural network is the best option to achieve the aforesaid objectives. Well correlation between the artificial neural network predicted results and experimental ones validate the developed technique of ascertaining the tool chatter severity.

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Ma, Hai Long, Ai Jun Tang, and Qing Kui Chen. "Dynamic Models of Stability Lobes of Milling Thin-Walled Plates." Advanced Materials Research 443-444 (January 2012): 622–27. http://dx.doi.org/10.4028/www.scientific.net/amr.443-444.622.

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In the process of milling thin-walled plate, chatter is one of the major limitations on productivity and part quality even for high speed and high precision milling machines. Therefore, it is necessary to avoid chatter with a suitable choice of cutting condition. This paper studies the dynamic stability models of milling the thin-walled plate by analyzing the geometrical relationship of cutting, and derives the mathematic expressions in theory. Moreover, this paper develops a three-dimensional lobes diagram of the spindle speed, the axial depth and the radial depth. Through the three-dimensional lobes, it is possible to choose the appropriate cutting parameters according to the dynamic behavior of the chatter system.

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El-Wardani, T., M. M. Sadek, and M. A. Younis. "Theoretical Analysis of Grinding Chatter." Journal of Engineering for Industry 109, no. 4 (November 1, 1987): 314–20. http://dx.doi.org/10.1115/1.3187134.

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A mathematical model is proposed for the prediction of the grinding process chatter. It considers the machine structure as a multidegree of freedom system and takes into account various parameters affecting the process stability such as the workpiece and grinding wheel regeneration, wheel loading and its elastic characteristics. This model is based on a nonlinear relationship with the time factor which is introduced by the loading effect. Three-dimensional stability charts were predicted for the simultaneous variation of both the grinding wheel wear and loading. These stability charts relate the grinding wheel and workpiece speeds to the instantaneous limiting width of grinding. The validity of this mathematical model has been assessed with the aid of a series of chatter tests which were carried out in specially designed experiments. These tests show good quantitative and qualitative correlation between the theoretical results and those experimentally obtained. It has been found that the level of stability decreases with time, indicating the possibility of chatter occurring at a stable width of cut.

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Sims, Neil D. "The Self-Excitation Damping Ratio: A Chatter Criterion for Time-Domain Milling Simulations." Journal of Manufacturing Science and Engineering 127, no. 3 (December 14, 2004): 433–45. http://dx.doi.org/10.1115/1.1948393.

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Regenerative chatter is known to be a key factor that limits the productivity of high speed machining. Consequently, a great deal of research has focused on developing predictive models of milling dynamics, to aid engineers involved in both research and manufacturing practice. Time-domain models suffer from being computationally intensive, particularly when they are used to predict the boundary of chatter stability, when a large number of simulation runs are required under different milling conditions. Furthermore, to identify the boundary of stability each simulation must run for sufficient time for the chatter effect to manifest itself in the numerical data, and this is a major contributor to the inefficiency of the chatter prediction process. In the present article, a new chatter criterion is proposed for time-domain milling simulations, that aims to overcome this drawback by considering the transient response of the modeled behavior, rather than the steady-state response. Using a series of numerical investigations, it is shown that in many cases the new criterion can enable the numerical prediction to be computed more than five times faster than was previously possible. In addition, the analysis yields greater detail concerning the nature of the chatter vibrations, and the degree of stability that is observed.

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Ozlu, Emre, and Erhan Budak. "Analytical Modeling of Chatter Stability in Turning and Boring Operations—Part II: Experimental Verification." Journal of Manufacturing Science and Engineering 129, no. 4 (March 14, 2007): 733–39. http://dx.doi.org/10.1115/1.2738119.

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In this part of the paper series, chatter experiments are conducted in order to verify the proposed stability models presented in the first part (Ozlu, E., and Budak, E., 2007, ASME J. Manuf. Sci. Eng., 129(4), pp. 726–732). Turning and boring chatter experiments are conducted for the cases where the tool or the workpiece is the most flexible component of the cutting system. In addition, chatter experiments demonstrating the effect of the insert nose radius on the stability limit are presented. Satisfactory agreement is observed between the analytical predictions and the experimental results.

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Altıntas¸, Y., S. Engin, and E. Budak. "Analytical Stability Prediction and Design of Variable Pitch Cutters." Journal of Manufacturing Science and Engineering 121, no. 2 (May 1, 1999): 173–78. http://dx.doi.org/10.1115/1.2831201.

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An analytical prediction of stability lobes for milling cutters with variable pitch angles is presented. The method requires cutting constants, number of teeth, and transfer function of cutter mounted on the machine tool as inputs to a chatter stability expression. The stability is formulated by transforming time varying directional cutting constants into time invariant constants. Constant regenerative time delay in uniform cutters is transformed into nonuniform multiple regenerative time delay for variable pitch cutters. The chatter free axial depth of cut is solved from the eigenvalues of stability expression, whereas the spindle speed is identified from regenerative phase delays. The proposed technique has been verified with extensive cutting tests and time domain simulations. The practical use of the analytical solution is demonstrated by an optimal tooth spacing design application which increases the chatter free depth of cuts significantly.

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Thompson, R. A. "On the Doubly Regenerative Stability of a Grinder: The Effect of Contact Stiffness and Wave Filtering." Journal of Engineering for Industry 114, no. 1 (February 1, 1992): 53–60. http://dx.doi.org/10.1115/1.2899758.

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In the interest of acquiring a physical understanding of the causes and growth of chatter in grinders, past studies of doubly regenerative stability by the author (Thompson, 1974, 1977; Hahn and Thompson, 1977) looked at unnaturally high workpiece rotational speeds, excluded the contribution of cutting zone contact stiffness, and did not consider the effect of workpiece wave filtering. By incorporating these effects into the past referenced work, this paper attempts to close the gap between basic understanding and actual grinder behavior. It is known that at low speeds chatter involving large numbers of lobe pairs is excited. This leads to a diffuse frequency spectrum. It is further shown that the effect of finite contact stiffness is to improve stability and that workpiece wave filtering has no effect on basic stability, but leads to self-limiting chatter. The approach to wave filtered quasistability is accompanied by a lowering of chatter frequency.

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Rusinek, Rafał, and Paweł Lajmert. "Chatter Detection in Milling of Carbon Fiber-Reinforced Composites by Improved Hilbert–Huang Transform and Recurrence Quantification Analysis." Materials 13, no. 18 (September 16, 2020): 4105. http://dx.doi.org/10.3390/ma13184105.

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In the paper, the problem of chatter vibration detection in the milling process of carbon fiber-reinforced plastic is investigated. Chatter analysis may be considered theoretically based on data from impact test of an end mill cutter. However, a stability region obtained in such way may not agree with the real one. Therefore, this paper presents a method that can predict chatter vibrations based on cutting force components measurements. At the beginning, a stability lobe diagram is created to establish the range of experimental test in the plane of tool rotational speed and depth of cut. Next, an experiment of composite milling is performed. The experimentally-measured time series of cutting forces are decomposed with the use of the improved Hilbert–Huang transform (HHT). To detect chatter, statistical methods and recurrence quantification analysis (RQA) are used. However, much better results are obtained when new chatter indexes are proposed. The indexes, derived directly from the HHT and RQA methods, can be used to build an effective chatter prediction system.

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Budak, E. "An Analytical Design Method for Milling Cutters With Nonconstant Pitch to Increase Stability, Part 2: Application." Journal of Manufacturing Science and Engineering 125, no. 1 (February 1, 2003): 35–38. http://dx.doi.org/10.1115/1.1536656.

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Chatter stability in milling can be improved significantly using variable pitch cutters. The pitch angles can be optimized for certain chatter frequency and spindle speed ranges using the analytical method presented in the first part of this two-part paper. In this part, the improvement of productivity and surface finish are demonstrated in three example applications. It is shown that chatter stability can be improved significantly even at slow cutting speeds by properly designing the pitch angles. A roughing example demonstrates substantially reduced peak milling forces which allows higher material removal rate.

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Han, Qing Kai, Tao Yu, Zhi Wei Zhang, and Bang Chun Wen. "Nonlinear Stability and Bifurcation of Multi-D.O.F. Chatter System in Grinding Process." Key Engineering Materials 304-305 (February 2006): 141–45. http://dx.doi.org/10.4028/www.scientific.net/kem.304-305.141.

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The nonlinear chatter in grinding machine system is discussed analytically in the paper. In higher speed grinding process, the self-excited chatter vibration is mostly induced by the change of grinding speed and grinding wheel shape. Here the grinding machine tool is viewed as a nonlinear multi-D.O.F. autonomous system, in which hysteretic factors of contact surfaces are also introduced. Firstly, the DOFs of the above system are reduced efficiently without changing its dynamic properties by utilizing the center manifold theorem and averaging method. Then, a low dimensional system and corresponding averaging equations are obtained. The stability and bifurcation of chatter system are discussed on the base of deduced averaging equations. It is proved that chatter occurs as a Hopf bifurcation emerging from the steady state at the origin of system. The theoretical analyses on the multi-DOF chattering system will lead to further understanding of the nonlinear mechanisms of higher speed grinding processes.

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Journal articles on the topic 'Chatter Stability'

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