Thin-walled parts have been widely employed as critical components in high-performance equipment due to the high specific strength and light weight.However,owing to their relatively weak rigidity and poor damping prop...Thin-walled parts have been widely employed as critical components in high-performance equipment due to the high specific strength and light weight.However,owing to their relatively weak rigidity and poor damping properties,chatter vibration is likely to occur during the milling process,which severely deteriorates surface quality and decreases machining productivity.Therefore,chatter suppression is essential for improving the dynamic machinability of thin-walled structures and has attracted extensive attention over the past few decades.This paper reviews the current state of the art in research concerning chatter suppression during the milling of thin-walled workpieces.In consideration of the dynamic characteristics of this process,the challenges in design and application of chatter attenuation methods are highlighted.Moreover,various chatter suppression techniques,involving passive,active,and semi-active methods,are comprehensively discussed in terms of basic concepts,working mechanism,optimal design,and application.Finally,future research opportunities in chatter mitigation technology for thin-wall milling are recommended.展开更多
Low-frequency structural vibrations caused by poor rigidity are one of the main obstacles limiting the machining efficiency of robotic milling.Existing vibration suppression strategies primarily focus on passive vibra...Low-frequency structural vibrations caused by poor rigidity are one of the main obstacles limiting the machining efficiency of robotic milling.Existing vibration suppression strategies primarily focus on passive vibration absorption at the robotic end and feedback control at the joint motor.Although these strategies have a certain vibration suppression effect,the limitations of robotic flexibility and the extremely limited applicable speed range remain to be overcome.In this study,a Magnetorheological Joint Damper(MRJD)is developed.The joint-mounted feature ensures machining flexibility of the robot,and the millisecond response time of the Magnetorheological Fluid(MRF)ensures a large effective spindle speed range.More importantly,the evolution law of the damping performance of MRJD was revealed based on a low-frequency chatter mechanism,which guarantees the application of MRJD in robotic milling machining.To analyze the influence of the robotic joint angle on the suppression effect of the MRJD,the joint braking coefficient and end braking coefficient were proposed.Parallel coordinate plots were used to visualize the joint range with the optimal vibration suppression effect.Finally,a combination of different postures and cutting parameters was used to verify the vibration suppression effect and feasibility of the joint angle optimization.The experimental results show that the MRJD,which directly improves the joint vibration resistance,can effectively suppress the low-frequency vibration of robotic milling under a variety of cutting conditions.展开更多
The possibility of the electric-hydraulic chattering technology and its application in the cold extrusion were presented.The conventional and electric-hydraulic chattering assisted backward extrusion processes were pe...The possibility of the electric-hydraulic chattering technology and its application in the cold extrusion were presented.The conventional and electric-hydraulic chattering assisted backward extrusion processes were performed on 6061 aluminum alloy billets at room temperature.The experimental results showed that 5.65% reduction in the extrusion load was attained if the die and ejector were vibrated at a frequency of 100 Hz and amplitude of 0.013 mm in the longitudinal direction.The friction coefficient at the billet and tool system interface determined from the finite element analysis（FEA） decreased from 0.2 without chattering to 0.1 with application of electric-hydraulic chattering.The higher values of instantaneous velocity and direction change of material flow were achieved during the chattering assisted backward extrusion process.The strain distribution of the chattering assisted backward extrusion billet revealed lower maximum strain and smoother strain distribution in comparison with that produced by the conventional extrusion method.展开更多
Considering the deficiency in milling process parameters selection, based on the modelling of dynamic milling force and the deduction of chatter stability limits, the chatter stability lobes simulation program for mil...Considering the deficiency in milling process parameters selection, based on the modelling of dynamic milling force and the deduction of chatter stability limits, the chatter stability lobes simulation program for milling is developed with MAT- LAB. The simulation optimization application software of dynamics was designed using engineering simulation software Visio Basic. The chatter stability lobes for milling, which can be used as an instruction guide for the selection of process parameters, are simulated with frequency response functions （FRFs） gained by hammer test. The validation and accuracy of the simulation algorithm are verified by experiments. The simulation method has been used in a factory with an excellent application effect.展开更多
A new method for suppressing cutting chatter is studied by adjusting servo parameters of the numerical control （NC） machine tool and controlling the limited cutting width. A model of the cutting system of the NC mac...A new method for suppressing cutting chatter is studied by adjusting servo parameters of the numerical control （NC） machine tool and controlling the limited cutting width. A model of the cutting system of the NC machine tool is established. It includes the mechanical system, the servo system and the cutting chatter system. Interactions between every two systems are shown in the model. The cutting system stability is simulated and relation curves between the limited cutting width and servo system parameters are described in the experiment. Simulation and experimental results show that there is a mapping relation between the limited cutting width and servo parameters of the NC machine tool, and the method is applicable and credible to suppress chatter.展开更多
An applicable method to control regenerative cutting chatter automatically based on the optimal regulation of spindle speed is introduced. The optimal value of the phase shift angle of the regenerative chatter signal ...An applicable method to control regenerative cutting chatter automatically based on the optimal regulation of spindle speed is introduced. The optimal value of the phase shift angle of the regenerative chatter signal between the two successive cuts is 270°. The cutting process can be adjusted from the unstable region to stable one whenever regenerative chatter occurs if the phase shift angle is kept 270° by the optimal regulation of spindle speed. The theoretical analysis and the experimental results prove that the optimal regulation of spindle speed can effectively control regenerative cutting chatter. In addition, a reliablelly optimal control system of reliable spindle speed is presented. There is no need for system identification of the machine tool, and it is easy to put this regenerative chatter control method into practice, so the method has excellent application prospect.展开更多
Chatter is a self-excited vibration of parts in machining systems. It is widely present across a range of cutting processes, and has an impact upon both efficiency and quality in production processing. A great deal of...Chatter is a self-excited vibration of parts in machining systems. It is widely present across a range of cutting processes, and has an impact upon both efficiency and quality in production processing. A great deal of research has been dedicated to the development of technologies that are able to predict and detect chatter. The purpose of these technologies is to facilitate the avoidance of chatter during cutting processes, which leads to better surface precision, higher productivity,and longer tool life. This paper summarizes the current state of the art in research regarding the problems of how to arrive at stable chatter prediction, chatter identification, and chatter control/-suppression, with a focus on milling processes. Particular focus is placed on the theoretical relationship between cutting chatter and process damping, tool runout, and gyroscopic effect, as well as the importance of this for chatter prediction. The paper concludes with some reflections regarding possible directions for future research in this field.展开更多
In order to build high accuracy integral dynamic models of cold rolling mill system, by analyzing the vibration process of cold rolling, the dynamic model of 4-h mill, including the rolling process model, the mill rol...In order to build high accuracy integral dynamic models of cold rolling mill system, by analyzing the vibration process of cold rolling, the dynamic model of 4-h mill, including the rolling process model, the mill roll stand structure model and the hydraulic servo system model is built. These three models are coupled and linearized, then the multiple input and multiple output （MIMO） linear transfer function model of single stand 4-h cold mill system is obtained. The model with the proposed data proves its validity, meanwhile the effects of different working conditions on the stability of cold rolling mill system have been discussed. Simulation resulsts show that the model accords with former models and has its own advancement. It contributes to the further study and supression of coupling vibraiton.展开更多
Currently, the modeling of cutting process mainly focuses on two aspects: one is the setup of the universal cutting force model that can be adapted to a broader cutting condition; the other is the setup of the exact c...Currently, the modeling of cutting process mainly focuses on two aspects: one is the setup of the universal cutting force model that can be adapted to a broader cutting condition; the other is the setup of the exact cutting force model that can accurately reflect a true cutting process. However, there is little research on the prediction of chatter stablity in milling. Based on the generalized mathematical model of inserted cutters introduced by ENGIN, an improved geometrical, mechanical and dynamic model for the vast variety of inserted cutters widely used in engineering applications is presented, in which the average directional cutting force coefficients are obtained by means of a numerical approach, thus leading to an analytical determination of stability lobes diagram (SLD) on the axial depth of cut. A new kind of SLD on the radial depth of cut is also created to satisfy the special requirement of inserted cutter milling. The corresponding algorithms used for predicting cutting forces, vibrations, dimensional surface finish and stability lobes in inserted cutter milling under different cutting conditions are put forward. Thereafter, a dynamic simulation module of inserted cutter milling is implemented by using hybrid program of Matlab with Visual Basic. Verification tests are conducted on a vertical machine center for Aluminum alloy LC4 by using two different types of inserted cutters, and the effectiveness of the model and the algorithm is verified by the good agreement of simulation result with that of cutting tests under different cutting conditions. The proposed model can predict the cutting process accurately under a variety of cutting conditions, and a high efficient and chatter-free milling operation can be achieved by a cutting condition optimization in industry applications.展开更多
T-slot milling is one of the most common milling processes in industry. Despite recent advances in machining technology, productivity of T-slot milling is usually limited due to the process limitations such as high cu...T-slot milling is one of the most common milling processes in industry. Despite recent advances in machining technology, productivity of T-slot milling is usually limited due to the process limitations such as high cutting forces and stability. If cutting conditions are not selected properly the process may result in the poor surface finish of the workpiece and the potential damage to the machine tool. Currently, the predication of chatter stability and determination of optimal cutting conditions based on the modeling of T-slot milling process is an effective way to improve the material removal rate（MRR） of a T-slot milling operation. Based on the geometrical model of the T-slot cutter, the dynamic cutting force model was presented in which the average directional cutting force coefficients were obtained by means of numerical approach, and leads to an analytical determination of stability lobes diagram（SLD） on the axial depth of cut. A new kind of SLD on the radial depth of cut was also created to satisfy the special requirement of T-slot milling. Thereafter, a dynamic simulation model of T-slot milling was implemented using Matlab software. In order to verify the effectiveness of the approach, the transfer functions of a typical cutting system in a vertical CNC machining center were measured in both feed and normal directions by an instrumented hammer and accelerators. Dynamic simulations were conducted to obtain the predicated SLD under specified cutting conditions with both the proposed model and CutPro~. Meanwhile, a set of cutting trials were conducted to reveal whether the cutting process under specified cutting conditions is stable or not. Both the simulation comparison and experimental verification demonstrated that the satisfactory coincidence between the simulated, the predicted and the experimental results. The chatter-free T-slot milling with higher MRR can be achieved under the cutting conditions determined according to the SLD simulation.展开更多
An analytical model for chatter aero-engine casings is presented in this paper stability prediction in bull-nose end milling of And the mechanics and dynamics variations due to the complex cutter and workpiece geomet...An analytical model for chatter aero-engine casings is presented in this paper stability prediction in bull-nose end milling of And the mechanics and dynamics variations due to the complex cutter and workpiece geometry are considered by analyzing the effects of the lead angle on the milling process. Firstly, the tool-workpiece engagement region is obtained by using a previously developed method and divided into several disk elements along the tool-axis direction. Secondly, a 3D dynamic model for stability limit calculation is developed and simplified into a 1D model in normal direction considering only the dominant mode of the workpiece. Then the cutting force coefficients, the start and exit angles corresponding to each disk element are determined. And the total stability lobe diagram is calculated using an iterative algorithm. Finally, several experimental tests are carried out to validate the feasibility and effectiveness of the proposed ~rediction approach.展开更多
In order to avoid the accuracy deterioration or tool damage caused by milling chatter, it is necessary to have an efficient and reliable diagnosis system that can on-line predict/detect the occur-rence of chatter. The...In order to avoid the accuracy deterioration or tool damage caused by milling chatter, it is necessary to have an efficient and reliable diagnosis system that can on-line predict/detect the occur-rence of chatter. The diagnosis/predicting system proposed is to on-line process and analysis the vi-bration signals of the milling machine measured by accelerometers. According to the analysis results, the system will be able to detect/predict the occurrence of the chatter. The diagnosis algorithm is, first, collecting both the normal signals and chatter signals from milling processes, and then, converting the signals through wavelet transform and fast Fourier transform （FFT）. Since the converted chatter sig-nals exhibit different characteristics from the normal signals, through defining the characteristic val-ues, such as root-mean-square value, max value, and ratio of peak value to root-mean-square value, etc, a diagnosis reference library that contains the distribution of these characteristic values is built for diagnosis. When a diagnosis is executing, the characteristic value of the measured signals is con-trasted with the diagnosis reference. The approach index which shows the possibility of occurrence of milling chatter will, then, be calculated through the diagnosis system. Cutting experiments are con-ducted to verify the proposed diagnosis system. The results show the success of early chatter detecting for the system.展开更多
Grinding chatter is a self?induced vibration which is unfavorable to precision machining processes. This paper proposes a forecasting method for grinding state identification based on bivarition empirical mode decompo...Grinding chatter is a self?induced vibration which is unfavorable to precision machining processes. This paper proposes a forecasting method for grinding state identification based on bivarition empirical mode decomposition(BEMD) and least squares support vector machine(LSSVM), which allows the monitoring of grinding chatter over time. BEMD is a promising technique in signal processing research which involves the decomposition of two?dimen?sional signals into a series of bivarition intrinsic mode functions(BIMFs). BEMD and the extraction criterion of its true BIMFs are investigated by processing a complex?value simulation chatter signal. Then the feature vectors which are employed as an amplification for the chatter premonition are discussed. Furthermore, the methodology is tested and validated by experimental data collected from a CNC guideway grinder KD4020 X16 in Hangzhou Hangji Machine Tool Co., Ltd. The results illustrate that the BEMD is a superior method in terms of processing non?stationary and nonlinear signals. Meanwhile, the peak to peak, real?time standard deviation and instantaneous energy are proven to be e ec?tive feature vectors which reflect the di erent grinding states. Finally, a LSSVM model is established for grinding status classification based on feature vectors, giving a prediction accuracy rate of 96%.展开更多
A new method is proposed to suppress chatter, in which the ultrasonic elliptical vibration is added on the cutting tool edge. It results in the fact that the rake face of tool is separated from the chip and the direct...A new method is proposed to suppress chatter, in which the ultrasonic elliptical vibration is added on the cutting tool edge. It results in the fact that the rake face of tool is separated from the chip and the direction of the frictional force between the rake face and the chip is reversed in each cycle of elliptical vibration cutting. The experimental investigations show that the chatter can be suppressed effectively by adding ultrasonic elliptical vibration on the cutting tool edge. In order to make clear the reason of chatter suppression, the mechanism of chatter suppression is analyzed theoretically from the viewpoint of energy.展开更多
By turning a specifically designed conical part, complete process of metal cutting, in which the chatter occurs and expands, is recorded and analyzed. This process exposes that chatter vibration has two characters cal...By turning a specifically designed conical part, complete process of metal cutting, in which the chatter occurs and expands, is recorded and analyzed. This process exposes that chatter vibration has two characters called continuity and break. The continuity character means that vibration extent enlarges continuously while chatter frequency is almost changeless as the cutting depth extends downwards continuously. The break one is that chatter frequency moves rapidly downwards to a lower level while chatter remains after the cutting depth reach another given value. It is confirmed through an exciting test that the two chatter frequencies obtained in chatter test belong to the natural frequencies of workpiece system and cutting tool system respectively. From the viewpoints of chatter energy supplying and chatter mass effect, the. chatter should occur on one of the two final executive components in its natural frequency. On this basis, a new chatter model with two chatter active bodies is proposed. This new model can better explain the above phenomenon, and adapt to chatter monitoring and improvement of component structure well.展开更多
The chattering characteristic of sliding mode control isanalyzed when it is applied in distributed control systems （DCSs）.For a DCS with random time delay and packet dropout, a discreteswitching system model with ti...The chattering characteristic of sliding mode control isanalyzed when it is applied in distributed control systems （DCSs）.For a DCS with random time delay and packet dropout, a discreteswitching system model with time varying sampling period isconstructed based on the time delay system method. The reachinglaw based sliding mode controller is applied in the proposedsystem. The exponential stability condition in the form of linearmatrix inequality is figured out based on the multi-Lyaponov functionmethod. Then, the chattering characteristic is analyzed for theswitching system, and a chattering region related with time varyingsampling period and external disturbance is proposed. Finally, numericalexamples are given to illustrate the validity of the analysisresult.展开更多
基金supported by the National Natural Science Foundation of China(Grant No.U22A20202)。
文摘Thin-walled parts have been widely employed as critical components in high-performance equipment due to the high specific strength and light weight.However,owing to their relatively weak rigidity and poor damping properties,chatter vibration is likely to occur during the milling process,which severely deteriorates surface quality and decreases machining productivity.Therefore,chatter suppression is essential for improving the dynamic machinability of thin-walled structures and has attracted extensive attention over the past few decades.This paper reviews the current state of the art in research concerning chatter suppression during the milling of thin-walled workpieces.In consideration of the dynamic characteristics of this process,the challenges in design and application of chatter attenuation methods are highlighted.Moreover,various chatter suppression techniques,involving passive,active,and semi-active methods,are comprehensively discussed in terms of basic concepts,working mechanism,optimal design,and application.Finally,future research opportunities in chatter mitigation technology for thin-wall milling are recommended.
基金supported by the National Natural Science Foundation of China(No.U20A20294)the National Natural Science Foundation of China(No.52322511)the National Natural Science Foundation of China(No.52188102).
文摘Low-frequency structural vibrations caused by poor rigidity are one of the main obstacles limiting the machining efficiency of robotic milling.Existing vibration suppression strategies primarily focus on passive vibration absorption at the robotic end and feedback control at the joint motor.Although these strategies have a certain vibration suppression effect,the limitations of robotic flexibility and the extremely limited applicable speed range remain to be overcome.In this study,a Magnetorheological Joint Damper(MRJD)is developed.The joint-mounted feature ensures machining flexibility of the robot,and the millisecond response time of the Magnetorheological Fluid(MRF)ensures a large effective spindle speed range.More importantly,the evolution law of the damping performance of MRJD was revealed based on a low-frequency chatter mechanism,which guarantees the application of MRJD in robotic milling machining.To analyze the influence of the robotic joint angle on the suppression effect of the MRJD,the joint braking coefficient and end braking coefficient were proposed.Parallel coordinate plots were used to visualize the joint range with the optimal vibration suppression effect.Finally,a combination of different postures and cutting parameters was used to verify the vibration suppression effect and feasibility of the joint angle optimization.The experimental results show that the MRJD,which directly improves the joint vibration resistance,can effectively suppress the low-frequency vibration of robotic milling under a variety of cutting conditions.
基金Project(51275475)supported by the National Natural Science Foundation of ChinaProject(2014BY001)supported by the Department of Education in Zhejiang Province,ChinaProject(2014EP0110)supported by the Key Laboratory of Special Purpose Equipment and Advanced Manufacturing Technology,Ministry of Education and Zhejiang Province,China
文摘The possibility of the electric-hydraulic chattering technology and its application in the cold extrusion were presented.The conventional and electric-hydraulic chattering assisted backward extrusion processes were performed on 6061 aluminum alloy billets at room temperature.The experimental results showed that 5.65% reduction in the extrusion load was attained if the die and ejector were vibrated at a frequency of 100 Hz and amplitude of 0.013 mm in the longitudinal direction.The friction coefficient at the billet and tool system interface determined from the finite element analysis（FEA） decreased from 0.2 without chattering to 0.1 with application of electric-hydraulic chattering.The higher values of instantaneous velocity and direction change of material flow were achieved during the chattering assisted backward extrusion process.The strain distribution of the chattering assisted backward extrusion billet revealed lower maximum strain and smoother strain distribution in comparison with that produced by the conventional extrusion method.
基金Tianjin Municipal Association of Higher Vocational&Technical Education Projects(No.XIV412)
文摘Considering the deficiency in milling process parameters selection, based on the modelling of dynamic milling force and the deduction of chatter stability limits, the chatter stability lobes simulation program for milling is developed with MAT- LAB. The simulation optimization application software of dynamics was designed using engineering simulation software Visio Basic. The chatter stability lobes for milling, which can be used as an instruction guide for the selection of process parameters, are simulated with frequency response functions （FRFs） gained by hammer test. The validation and accuracy of the simulation algorithm are verified by experiments. The simulation method has been used in a factory with an excellent application effect.
文摘A new method for suppressing cutting chatter is studied by adjusting servo parameters of the numerical control （NC） machine tool and controlling the limited cutting width. A model of the cutting system of the NC machine tool is established. It includes the mechanical system, the servo system and the cutting chatter system. Interactions between every two systems are shown in the model. The cutting system stability is simulated and relation curves between the limited cutting width and servo system parameters are described in the experiment. Simulation and experimental results show that there is a mapping relation between the limited cutting width and servo parameters of the NC machine tool, and the method is applicable and credible to suppress chatter.
文摘An applicable method to control regenerative cutting chatter automatically based on the optimal regulation of spindle speed is introduced. The optimal value of the phase shift angle of the regenerative chatter signal between the two successive cuts is 270°. The cutting process can be adjusted from the unstable region to stable one whenever regenerative chatter occurs if the phase shift angle is kept 270° by the optimal regulation of spindle speed. The theoretical analysis and the experimental results prove that the optimal regulation of spindle speed can effectively control regenerative cutting chatter. In addition, a reliablelly optimal control system of reliable spindle speed is presented. There is no need for system identification of the machine tool, and it is easy to put this regenerative chatter control method into practice, so the method has excellent application prospect.
基金supported by Projects of International Cooperation and Exchanges NSFC (51720105009)the National Natural Science Foundation of China (No. 51575147)the Youth Talent Support Program of Harbin University of Science and Technology (201507)
文摘Chatter is a self-excited vibration of parts in machining systems. It is widely present across a range of cutting processes, and has an impact upon both efficiency and quality in production processing. A great deal of research has been dedicated to the development of technologies that are able to predict and detect chatter. The purpose of these technologies is to facilitate the avoidance of chatter during cutting processes, which leads to better surface precision, higher productivity,and longer tool life. This paper summarizes the current state of the art in research regarding the problems of how to arrive at stable chatter prediction, chatter identification, and chatter control/-suppression, with a focus on milling processes. Particular focus is placed on the theoretical relationship between cutting chatter and process damping, tool runout, and gyroscopic effect, as well as the importance of this for chatter prediction. The paper concludes with some reflections regarding possible directions for future research in this field.
基金Item Sponsored by National Natural Science Foundation of China(60374032)Beijing Municipal Education Commission Key Discipline Control Theory and Control Engineering of China(XK100080537)
文摘In order to build high accuracy integral dynamic models of cold rolling mill system, by analyzing the vibration process of cold rolling, the dynamic model of 4-h mill, including the rolling process model, the mill roll stand structure model and the hydraulic servo system model is built. These three models are coupled and linearized, then the multiple input and multiple output （MIMO） linear transfer function model of single stand 4-h cold mill system is obtained. The model with the proposed data proves its validity, meanwhile the effects of different working conditions on the stability of cold rolling mill system have been discussed. Simulation resulsts show that the model accords with former models and has its own advancement. It contributes to the further study and supression of coupling vibraiton.
基金supported by Hunan Provincial Natural Science Foundation of China (Grant Nos. 10JJ2040, 11JJ3055)National Major Science and Technology Special Projects of China (Grant No.2012ZX04011-011)+1 种基金Postdoctoral Science Funded Project of China (GrantNo. 20110490261)Hunan Provincial 12th Five-year Plan Key Disciplines of China (Grant No. 2012-42)
文摘Currently, the modeling of cutting process mainly focuses on two aspects: one is the setup of the universal cutting force model that can be adapted to a broader cutting condition; the other is the setup of the exact cutting force model that can accurately reflect a true cutting process. However, there is little research on the prediction of chatter stablity in milling. Based on the generalized mathematical model of inserted cutters introduced by ENGIN, an improved geometrical, mechanical and dynamic model for the vast variety of inserted cutters widely used in engineering applications is presented, in which the average directional cutting force coefficients are obtained by means of a numerical approach, thus leading to an analytical determination of stability lobes diagram (SLD) on the axial depth of cut. A new kind of SLD on the radial depth of cut is also created to satisfy the special requirement of inserted cutter milling. The corresponding algorithms used for predicting cutting forces, vibrations, dimensional surface finish and stability lobes in inserted cutter milling under different cutting conditions are put forward. Thereafter, a dynamic simulation module of inserted cutter milling is implemented by using hybrid program of Matlab with Visual Basic. Verification tests are conducted on a vertical machine center for Aluminum alloy LC4 by using two different types of inserted cutters, and the effectiveness of the model and the algorithm is verified by the good agreement of simulation result with that of cutting tests under different cutting conditions. The proposed model can predict the cutting process accurately under a variety of cutting conditions, and a high efficient and chatter-free milling operation can be achieved by a cutting condition optimization in industry applications.
基金supported by National Science and Technology Support Program of China (Grant No. 2006BAF01B09-03)the Research Fund for the Doctoral Program of Higher Education of China (Grant No. 200800060010)Hunan Provincial Educational Department Scientific Research Project of China (Grant No. 08D096)
文摘T-slot milling is one of the most common milling processes in industry. Despite recent advances in machining technology, productivity of T-slot milling is usually limited due to the process limitations such as high cutting forces and stability. If cutting conditions are not selected properly the process may result in the poor surface finish of the workpiece and the potential damage to the machine tool. Currently, the predication of chatter stability and determination of optimal cutting conditions based on the modeling of T-slot milling process is an effective way to improve the material removal rate（MRR） of a T-slot milling operation. Based on the geometrical model of the T-slot cutter, the dynamic cutting force model was presented in which the average directional cutting force coefficients were obtained by means of numerical approach, and leads to an analytical determination of stability lobes diagram（SLD） on the axial depth of cut. A new kind of SLD on the radial depth of cut was also created to satisfy the special requirement of T-slot milling. Thereafter, a dynamic simulation model of T-slot milling was implemented using Matlab software. In order to verify the effectiveness of the approach, the transfer functions of a typical cutting system in a vertical CNC machining center were measured in both feed and normal directions by an instrumented hammer and accelerators. Dynamic simulations were conducted to obtain the predicated SLD under specified cutting conditions with both the proposed model and CutPro~. Meanwhile, a set of cutting trials were conducted to reveal whether the cutting process under specified cutting conditions is stable or not. Both the simulation comparison and experimental verification demonstrated that the satisfactory coincidence between the simulated, the predicted and the experimental results. The chatter-free T-slot milling with higher MRR can be achieved under the cutting conditions determined according to the SLD simulation.
基金supported by the National Basic Research Program of China(No.2013CB035802)the 111 Project of China(No.B13044)
文摘An analytical model for chatter aero-engine casings is presented in this paper stability prediction in bull-nose end milling of And the mechanics and dynamics variations due to the complex cutter and workpiece geometry are considered by analyzing the effects of the lead angle on the milling process. Firstly, the tool-workpiece engagement region is obtained by using a previously developed method and divided into several disk elements along the tool-axis direction. Secondly, a 3D dynamic model for stability limit calculation is developed and simplified into a 1D model in normal direction considering only the dominant mode of the workpiece. Then the cutting force coefficients, the start and exit angles corresponding to each disk element are determined. And the total stability lobe diagram is calculated using an iterative algorithm. Finally, several experimental tests are carried out to validate the feasibility and effectiveness of the proposed ~rediction approach.
基金Selected from Proceedings of the 7th International Conference on Frontierof Design and Manufacturing(ICFDM’2006).
文摘In order to avoid the accuracy deterioration or tool damage caused by milling chatter, it is necessary to have an efficient and reliable diagnosis system that can on-line predict/detect the occur-rence of chatter. The diagnosis/predicting system proposed is to on-line process and analysis the vi-bration signals of the milling machine measured by accelerometers. According to the analysis results, the system will be able to detect/predict the occurrence of the chatter. The diagnosis algorithm is, first, collecting both the normal signals and chatter signals from milling processes, and then, converting the signals through wavelet transform and fast Fourier transform （FFT）. Since the converted chatter sig-nals exhibit different characteristics from the normal signals, through defining the characteristic val-ues, such as root-mean-square value, max value, and ratio of peak value to root-mean-square value, etc, a diagnosis reference library that contains the distribution of these characteristic values is built for diagnosis. When a diagnosis is executing, the characteristic value of the measured signals is con-trasted with the diagnosis reference. The approach index which shows the possibility of occurrence of milling chatter will, then, be calculated through the diagnosis system. Cutting experiments are con-ducted to verify the proposed diagnosis system. The results show the success of early chatter detecting for the system.
基金National Natural Science Foundation of China(Grant No.51475432)Zhejiang Provincial National Natural Science Foundation of China(Grant No.LZ13E050003)State Key Program of National Natural Science of China(Grant Nos.U1234207,U1709210)
文摘Grinding chatter is a self?induced vibration which is unfavorable to precision machining processes. This paper proposes a forecasting method for grinding state identification based on bivarition empirical mode decomposition(BEMD) and least squares support vector machine(LSSVM), which allows the monitoring of grinding chatter over time. BEMD is a promising technique in signal processing research which involves the decomposition of two?dimen?sional signals into a series of bivarition intrinsic mode functions(BIMFs). BEMD and the extraction criterion of its true BIMFs are investigated by processing a complex?value simulation chatter signal. Then the feature vectors which are employed as an amplification for the chatter premonition are discussed. Furthermore, the methodology is tested and validated by experimental data collected from a CNC guideway grinder KD4020 X16 in Hangzhou Hangji Machine Tool Co., Ltd. The results illustrate that the BEMD is a superior method in terms of processing non?stationary and nonlinear signals. Meanwhile, the peak to peak, real?time standard deviation and instantaneous energy are proven to be e ec?tive feature vectors which reflect the di erent grinding states. Finally, a LSSVM model is established for grinding status classification based on feature vectors, giving a prediction accuracy rate of 96%.
文摘A new method is proposed to suppress chatter, in which the ultrasonic elliptical vibration is added on the cutting tool edge. It results in the fact that the rake face of tool is separated from the chip and the direction of the frictional force between the rake face and the chip is reversed in each cycle of elliptical vibration cutting. The experimental investigations show that the chatter can be suppressed effectively by adding ultrasonic elliptical vibration on the cutting tool edge. In order to make clear the reason of chatter suppression, the mechanism of chatter suppression is analyzed theoretically from the viewpoint of energy.
基金National Natural Science Foundation of China(No, 50575232).
文摘By turning a specifically designed conical part, complete process of metal cutting, in which the chatter occurs and expands, is recorded and analyzed. This process exposes that chatter vibration has two characters called continuity and break. The continuity character means that vibration extent enlarges continuously while chatter frequency is almost changeless as the cutting depth extends downwards continuously. The break one is that chatter frequency moves rapidly downwards to a lower level while chatter remains after the cutting depth reach another given value. It is confirmed through an exciting test that the two chatter frequencies obtained in chatter test belong to the natural frequencies of workpiece system and cutting tool system respectively. From the viewpoints of chatter energy supplying and chatter mass effect, the. chatter should occur on one of the two final executive components in its natural frequency. On this basis, a new chatter model with two chatter active bodies is proposed. This new model can better explain the above phenomenon, and adapt to chatter monitoring and improvement of component structure well.
基金supported by the National Natural Science Fundation of China(5147618751506221)+1 种基金the Natural Science Basic Research Plan in Shaanxi Province of China(2015JQ51792015JM5207)
文摘The chattering characteristic of sliding mode control isanalyzed when it is applied in distributed control systems （DCSs）.For a DCS with random time delay and packet dropout, a discreteswitching system model with time varying sampling period isconstructed based on the time delay system method. The reachinglaw based sliding mode controller is applied in the proposedsystem. The exponential stability condition in the form of linearmatrix inequality is figured out based on the multi-Lyaponov functionmethod. Then, the chattering characteristic is analyzed for theswitching system, and a chattering region related with time varyingsampling period and external disturbance is proposed. Finally, numericalexamples are given to illustrate the validity of the analysisresult.
