Skip to main content
Log in

Chatter stability prediction for high-speed milling through a novel experimental-analytical approach

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

A Correction to this article was published on 07 March 2018

This article has been updated

Abstract

Chatter prediction is crucial in high-speed milling, since at high speed, a significant increase of productivity can be achieved by selecting optimal set of chatter-free cutting parameters. However, chatter predictive models show reduced accuracy at high speed due to machine dynamics, acquired in stationary condition (i.e., without spindle rotating), but changing with spindle speed. This paper proposes a hybrid experimental-analytical approach to identify tool-tip frequency response functions during cutting operations, with the aim of improving chatter prediction at high speed. The method is composed of an efficient test and an analytical identification technique based on the inversion of chatter predictive model. The proposed technique requires few cutting tests and a microphone to calculate speed-dependent chatter stability in a wide range of spindle speed, without the need of stationary frequency response function (FRF) identification. Numerical and experimental validations are presented to show the method implementation and assess its accuracy. As proven in the paper, computed speed-dependent tool-tip FRF in a specific configuration (i.e., slotting) can be used to predict chatter occurrence in any other conditions with the same tool.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

Change history

  • 07 March 2018

    The original version of this article contained a mistake. In the caption of Fig. 4, “!c =!n eq.” is not correct.

References

  1. Altintas Y (2012) Manufacturing automation: metal cutting mechanics, machine tool vibrations, and CNC design

  2. Quintana G, Ciurana J (2011) Chatter in machining processes: a review. Int J Mach Tools Manuf 51:363–376

    Article  Google Scholar 

  3. Grossi N, Sallese L, Scippa A, Campatelli G (2014) Chatter stability prediction in milling using speed-varying cutting force coefficients. Procedia CIRP 14:170–175

    Article  Google Scholar 

  4. Grossi N, Montevecchi F, Scippa A, Campatelli G (2015) 3D finite element modeling of holder-tool assembly for stability prediction in milling. Procedia CIRP 31:527–532

    Article  Google Scholar 

  5. Grossi N, Scippa A, Montevecchi F, Campatelli G (2016) A novel experimental-numerical approach to modeling machine tool dynamics for chatter stability prediction. J Adv Mech Des Syst Manuf 10:1–10

    Article  Google Scholar 

  6. Chen JS, Hwang YW (2006) Centrifugal force induced dynamics of a motorized high-speed spindle. Int J Adv Manuf Technol 30:10–19

    Article  Google Scholar 

  7. Cao H, Holkup T, Altintas Y (2011) A comparative study on the dynamics of high speed spindles with respect to different preload mechanisms. Int J Adv Manuf Technol 57:871–883

    Article  Google Scholar 

  8. Gagnol V, Bouzgarrou BC, Ray P, Barra C (2007) Model-based chatter stability prediction for high-speed spindles. Int J Mach Tools Manuf 47:1176–1186

    Article  Google Scholar 

  9. Cao H, Li B, He Z (2012) Chatter stability of milling with speed-varying dynamics of spindles. Int J Mach Tools Manuf 52:50–58

    Article  Google Scholar 

  10. Bediz B, Arda Gozen B, Korkmaz E, Burak Ozdoganlar O (2014) Dynamics of ultra-high-speed (UHS) spindles used for micromachining. Int J Mach Tools Manuf 87:27–38

    Article  Google Scholar 

  11. Matsubara A, Yamazaki T, Ikenaga S (2013) Non-contact measurement of spindle stiffness by using magnetic loading device. Int J Mach Tools Manuf 71:20–25

    Article  Google Scholar 

  12. Rantatalo M, Aidanpää J-O, Göransson B, Norman P (2007) Milling machine spindle analysis using FEM and non-contact spindle excitation and response measurement. Int J Mach Tools Manuf 47:1034–1045

    Article  Google Scholar 

  13. Lamraoui M, El Badaoui M, Guilleti F (2016) Chatter stability prediction for CNC machine tool in operating condition through operational modal analysis. Mech Ind 17:402

    Article  Google Scholar 

  14. Özşahin O, Budak E, Özgüven HN (2011) Investigating dynamics of machine tool spindles under operational conditions. Adv Mater Res 223:610–621

    Article  Google Scholar 

  15. Özşahin O, Budak E, Özgüven HN (2015) In-process tool point FRF identification under operational conditions using inverse stability solution. Int J Mach Tools Manuf 89:64–73

    Article  Google Scholar 

  16. Suzuki N, Kurata Y, Kato T, Hino R, Shamoto E (2012) Identification of transfer function by inverse analysis of self-excited chatter vibration in milling operations. Precis Eng 36:568–575

    Article  Google Scholar 

  17. Kruth JP, Liu AMM, Vanherck P, Lauwers B (2002) A strategy for selection of optimal cutting parameter in high-speed milling to avoid chatter vibration. Int J Prod Eng Comput 4:35–42

    Google Scholar 

  18. Ahmadi K, Altintas Y (2014) Identification of machining process damping using output-only modal analysis. J Manuf Sci Eng 136:51017

    Article  Google Scholar 

  19. Budak E, Tunc LT (2010) Identification and modeling of process damping in turning and milling using a new approach. CIRP Ann - Manuf Technol 59:403–408

    Article  Google Scholar 

  20. Budak E, Altintaş Y (1998) Analytical prediction of chatter stability in milling—part I: general formulation. J Dyn Syst Meas Control 120:22

    Article  Google Scholar 

  21. Muñoa J, Zatarain M, Dombovari Z, Yang Y (2009) Effect of mode interaction on stability of milling processes. 12th CIRP Conf. Model. Mach. Oper

  22. Zatarain M, Bediaga I, Muñoa J, Insperger T (2010) Analysis of directional factors in milling: importance of multi-frequency calculation and of the inclusion of the effect of the helix angle. Int J Adv Manuf Technol 47:535–542

    Article  Google Scholar 

  23. Insperger T, Stépán G (2002) Semi-discretization method for delayed systems. Int J Numer Methods Eng 55:503–518

    Article  MathSciNet  MATH  Google Scholar 

  24. Scippa A, Montevecchi F, Grossi N, Sallese L, Campatelli G (2015) Time domain simulation model for active fixturing in milling. Proc. 8th Int. Conf. Lead. Edge Manuf. 21st Century, LEM 2015

  25. Grossi N, Scippa A, Sallese L, Sato R, Campatelli G (2015) Spindle speed ramp-up test: a novel experimental approach for chatter stability detection. Int J Mach Tools Manuf 89:221–230

    Article  Google Scholar 

  26. Faassen RPH, van de Wouw N, Oosterling JAJ, Nijmeijer H (2003) Prediction of regenerative chatter by modelling and analysis of high-speed milling. Int J Mach Tools Manuf 43:1437–1446

    Article  Google Scholar 

  27. Quintana G, Ciurana J, Teixidor D (2008) A new experimental methodology for identification of stability lobes diagram in milling operations. Int J Mach Tools Manuf 48:1637–1645

    Article  Google Scholar 

  28. Grossi N, Sallese L, Scippa A, Campatelli G (2015) Speed-varying cutting force coefficient identification in milling. Precis Eng 42:321–334

    Article  Google Scholar 

  29. Ertürk A, Özgüven HN, Budak E (2007) Effect analysis of bearing and interface dynamics on tool point FRF for chatter stability in machine tools by using a new analytical model for spindle–tool assemblies. Int J Mach Tools Manuf 47:23–32

    Article  Google Scholar 

  30. Altintas Y, Stepan G, Merdol D, Dombovari Z (2008) Chatter stability of milling in frequency and discrete time domain. CIRP J Manuf Sci Technol 1:35–44

    Article  Google Scholar 

  31. Comak A, Ozsahin O, Altintas Y (2016) Chatter stability of milling operations with asymmetric cutter dynamics in rotating coordinates. J Manuf Sci Eng 1–7

  32. Montevecchi F, Grossi N, Scippa A, Campatelli G (2016) Improved RCSA technique for efficient tool-tip dynamics prediction. Precis Eng 44:152–162

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to N. Grossi.

Additional information

A correction to this article is available online at https://doi.org/10.1007/s00170-018-1763-x.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Grossi, N., Montevecchi, F., Sallese, L. et al. Chatter stability prediction for high-speed milling through a novel experimental-analytical approach. Int J Adv Manuf Technol 89, 2587–2601 (2017). https://doi.org/10.1007/s00170-016-9832-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-016-9832-5

Keywords

Navigation