Prediction and Avoidance of Chatter in Milling of Thin-Walled Structure

Abstract:

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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.

Info:

Periodical:

Key Engineering Materials (Volumes 407-408)

Edited by:

Fan Rui, Qiao Lihong, Chen Huawei, Ochi Akio, Usuki Hiroshi and Sekiya Katsuhiko

Pages:

404-407

DOI:

10.4028/www.scientific.net/KEM.407-408.404

Citation:

H. Sasahara and Y. Naito, "Prediction and Avoidance of Chatter in Milling of Thin-Walled Structure", Key Engineering Materials, Vols. 407-408, pp. 404-407, 2009

Online since:

February 2009

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Price:

$38.00

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[2] Spindle speed min-1 Axial depth of cut mm.

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[2] 1. 5 1. 0 0. 5 Axial depth of cut [mm] Stable Unstable Fig. 6 Stability lobe diagram for crossed-thin-walls structure Tool diameter=10mm, 2 flutes, Rd =0. 5mm, Upcut, Kt=580MPa, Kr=0. 289, ωA1=2, 981Hz, ωA2=7, 824Hz, ωA3=8, 853Hz, kA=0. 0391MN/m, ξ=0. 006, ωB1=8, 853Hz, kB=0. 4177MN/m, ξ=0. 006, ωC1=8, 853Hz, kC=0. 1283MN/m, ξ=0. 006, ωD1=6, 055Hz, kA=0. 2929MN/m, ξ=0. 006 A B D C A B D C A B D C mode1mode1 mode2mode2 mode3mode3 Fig. 5 Modal shapes of crossed-thin-walls structure.

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