Investigation of Chatter Vibration in End-Milling Process by Considering Coupled System Model

Kosuke Hattori; Hiroyuki Kodama; Toshiki Hirogaki; Eiichhi Aoyama

doi:10.4028/www.scientific.net/AMR.939.201

Paper Titles

Application of Idling Stop Technology for Servo Motors in Machine Tool Operations to Reduce Electric Power Consumption
p.169

Applications of Optical Path Length Compensation Technology for High Power CO₂ Laser Cutting Process
p.177

Bonding PDMS Microfluidic Devices to PMMA and Glass Substrate Using Pulsed UV Laser Technology
p.186

Finite Element Modeling of the Effect of Tool Rake Angle on Cutting Force and Tool Temperature during High Speed Machining of AISI 1045 Steel
p.194

Investigation of Chatter Vibration in End-Milling Process by Considering Coupled System Model
p.201

Micro Cutting of Biliary Stent with Nanosecond Fiber Laser System
p.209

Temperature Distribution of Micro Milling Process due to Uncut Chip Thickness
p.214

The Use of Supports to Fast Fabrication of Plastic Parts
p.222

Effect of Optical Properties Characteristic Polymethylmethacrylate Using UV Laser Direct-Structuring
p.230

HomeAdvanced Materials ResearchAdvanced Materials Research Vol. 939Investigation of Chatter Vibration in End-Milling...

Investigation of Chatter Vibration in End-Milling Process by Considering Coupled System Model

Abstract:

Chatter vibration in cutting processes usually leads to surface finish degradation, tool damage, cutting noise, energy loss, etc. Self-excited vibration particularly seems to be a problem that is easily increased to large vibration. The regenerative effect is considered as one of the causes of chatter vibration. Although the chatter vibration occurs in various types of processing, the end-milling is a typical process that seems to cause the chatter vibration due to a lack of rigidity of one or more parts of the machine tools, cutting tool, and work-piece. The aim of our research is to propose a simple method to control chatter vibration of the end-milling process on the basis of a coupling model integrating the related various elements. In this study, hammering tests were carried out to measure the transfer function of a machine tool and cutting tool system, which seems to cause vibration. By comparing these results, finite elemental method (FEM) analysis models were constructed. Additionally, cutting experiments were carried out to confirm the chatter vibration frequencies in end-milling with a machining center. In the hammering tests, impulse hammer and multiple acceleration pick-ups are connected to a multi-channel FFT analyzer and estimate the natural frequencies and natural vibration modes. A simplified FEM model is proposed by circular section stepped beam elements on the basis of the hammering test results, considering a coupling effect. In comparisons of the calculated results and hammering test results, the vibration modes are in good agreement. As a result, the proposed model accurately predicts the chatter vibration considering several effects among the relating elements in end-milling. Moreover, it can be seen that the chatter vibration is investigated from a viewpoint of the integrating model of the end-milling process.

You might also be interested in these eBooks

Advances in Materials and Processing Technologies XVI

View Preview

Info:

Periodical:

Advanced Materials Research (Volume 939)

Pages:

201-208

DOI:

https://doi.org/10.4028/www.scientific.net/AMR.939.201

Citation:

Cite this paper

Online since:

May 2014

Authors:

Kosuke Hattori*, Hiroyuki Kodama, Toshiki Hirogaki, Eiichhi Aoyama

Keywords:

Chatter Vibration, End-Milling, Finite Element Method (FEM), Impact Test, Machine Tool

Export:

RIS, BibTeX

Price:

Permissions:

Request Permissions

* - Corresponding Author

References

[1] Norikazu Suzuki, Chatter Vibration in Cutting Process, Journal of JSPE, Vol. 76, No. 3 (2010), pp.280-284, 404-408. (in Japanese).

Google Scholar

[2] Y. S. Chiou, E. S. Chung, S. Y. Liang, Analysis of Tool Wear Effect on Chatter Stability in Turning, Int. J. Mech. Sci., Vol. 37, No. 4 (1995), pp.391-404.

DOI: 10.1016/0020-7403(94)00070-z

Google Scholar

[3] Guillem Quintana, Joaquim Ciurana, Chatter in Machining Processes: A Review, International Journal of Machine Tools & Manufacture, Vol. 51(2011), pp.363-376.

DOI: 10.1016/j.ijmachtools.2011.01.001

Google Scholar

[4] Altintas, M. Eynial, H. Onozuka, Identification of Dynamic Cutting Force Coefficients and Chatter Stability with Process Damping, CIRP, Manufacturing Technology, Vol. 57 (2008), pp.371-374.

DOI: 10.1016/j.cirp.2008.03.048

Google Scholar

[5] Takuya Kojima, Norikazu Suzuki, Eiji Shiyamoto, New Design Method of Unequal Pitch Tool to Simultaneously Inhibit the Regeneration Effect of Multiple Mode, JSPE, (2010), pp.181-182. (in Japanese).

Google Scholar

[6] Y. Altintas, E. Budak, Analytical Prediction of Stability Lobes in Milling, Annals of the CIRP, Vol. 44, No. 1 (1995), pp.357-362.

DOI: 10.1016/s0007-8506(07)62342-7

Google Scholar

[7] Ivana Kovacic, The Chatter Vibrations in Metal Cutting - Theoretical Approach, Mechanical Engineering, Vol. 1, No. 5 (1998), pp.581-593.

Google Scholar