Sharif Digital Repository

Self-excited and forced vibrations are important topics in machining processes because their occurrence results in poor surface finish, increase in tool wear and reduction of material removal rate. In this paper, turning process is modeled as a single degree of freedom (SDOF) dynamic system including quadratic and cubic structural nonlinearities. The effect of tool flank wear, as a contact force between the workpiece and tool, is addressed vigorously. Multiple scale method is used to find the solution of the nonlinear delay-differential equation including regenerative chatter, forced excitation and tool wear. During the stability analysis, it is shown that width of cut can be considered as... 

Self-excited and forced vibrations are important topics in machining processes because their occurrence results in poor surface finish, increase in tool wear and hampers productivity. In this paper, turning process is modeled as a SDOF dynamic system including quadratic and cubic structural nonlinearities. The effect of tool flank wear, as a contact force between the work-piece and tool, is addressed vigorously. Multiple scale method is used to find the solution of the nonlinear dynamic equation including regenerative chatter, forced excitation and tool wear. It is shown that, width of cut can be considered as the bifurcation parameter of the system. Primary, super-harmonic and sub-harmonic... 

Chatter suppression is an important topic in any type of machining process. In this paper, orthogonal cutting process is modeled as a single degree of freedom dynamic system. A nonlinear delay differential equation is presented that models flank wear of the tool. Uncertainties in cutting velocity, tool wear size and parameters of the dynamic model are included in the model of cutting process. The force provided by a piezo-actuator is taken as the control input of the system. A sliding mode control scheme is used and an effective control law is derived which suppresses the chatter vibration. Results for two distinct cases of a sharp tool and a worn tool are presented and compared which shows... 

In this paper, bifurcation analysis is performed for the nonlinear milling process under sub-harmonic resonance and regenerative chatter, with tool wear and process damping effects. Multiple-scales approach is used to construct analytical approximate solutions for non-autonomous parametrically excited equations of the system with time delay terms. The new bifurcation parameters are the detuning parameter (deviation of the tooth passing frequency from three times of the chatter frequency), damping ratio (affected by process damping) and tool wear width. Jump phenomenon and multi-values responses are observed in the first order solution under sub-harmonic resonance condition. Periodic,... 

Self-excited and forced vibrations are important topics in machining processes because their occurrence results in poor surface finish, increase in tool wear and hampers productivity. In this paper, turning process is modeled as a SDOF dynamic system including quadratic and cubic structural nonlinearities. The effect of tool flank wear, as a contact force between the work-piece and tool, is addressed vigorously. Multiple scale method is used to find the solution of the nonlinear dynamic equation including regenerative chatter, forced excitation and tool wear. It is shown that, width of cut can be considered as the bifurcation parameter of the system. Primary, super-harmonic and sub-harmonic... 

A time domain approach is used to study the cutting conditions in reaming process that leads the system to regenerative chatter vibrations. The dynamic analysis of the system includes inertia of the tool, centripetal and Coriolis terms, damping and the first mode bending of reamer. A model of cutting forces proportional to chip cross sectional area and process damping proportional to cutting speed is considered. Numerical simulation based on the Euler integration scheme is carried out to obtain time domain solution of the equation. Despite linearization in force modelling, the model is nonlinear due to the change in the tool engagement area. Another nonlinearity included in the model jumping... 

Dynamic vibration absorbers are used as semi-active controllers to reduce the undesirable vibrations in many applications such as electrical transmission lines, helicopters, gas turbines, engines, bridges and etc. One type of these absorbers is tunable vibration absorber (TVA). In this paper, regenerative chatter in an orthogonal turning process is suppressed using a (TVA). It is shown that TVA can modify the frequency response function of the cutting tool so as to improve cutting stability in turning process. In addition, tool wear is an important factor which works as a positive damping and helps the chatter suppression beside exertion of the TVA. Finally, using the SIMULINK Toolbox of... 

In this paper, an extended dynamic model of peripheral milling process including process damping, structural and cutting force nonlinearities is presented. Cutting forces are described through a third-order polynomial function of chip thickness while a cubic nonlinear function is considered for the structural stiffness. Under stable and regenerative chatter conditions and using Fourier series components, closed form expressions for the nonlinear cutting forces are derived. Parameters of the proposed model are identified through a set of experiments. For this purpose, modal experiments and measurement of cutting forces (at various feed rates) are performed to determine the modal parameters... 

For various types of materials, milling process is extensively used to generate complex shapes with high quality. During the process and to achieve high removal rate, precision and better surface finish, chatter suppression is of great importance. An extended model of the milling process is presented in which the cutting forces are described as a third-order nonlinear function of chip thickness. Uncertainties associated with the process and tool parameters are also included to achieve a more realistic model. To suppress regenerative chatter, an H∞ robust control is designed based on µ-synthesis with DK-iteration algorithm. The controller guarantees the robust stability and performance of... 

In the machining processes, vibration suppression is crucial in order to achieve the high precision as well as high-quality surface and increase of the material removal rate. In this paper, an adaptive sliding mode control approach is presented to supress the chattering phenomenon in the boring process in the presence of model uncertainties and unmodeled dynamics. The boring bar is modeled as a cantilever Euler–Bernoulli beam, which is actuated by a piezo-actuator located at the bar's end. As a more realistic model, the cutting tool is modeled as an added mass at the bar's end. In order to derive the equations of motion, mode summation method with inclusion the first three modes of vibration... 

Chatter suppression is an important topic in any type of machining process. In this paper, orthogonal cutting process is modeled as a single degree of freedom dynamic system. A nonlinear delay differential equation is presented that models flank wear of the tool. Uncertainties in cutting velocity, tool wear size and parameters of the dynamic model are included in the model of cutting process. The force provided by a piezo-actuator is taken as the control input of the system. A sliding mode control scheme is used and an effective control law is derived which suppresses the chatter vibration. Results for two distinct cases of a sharp tool and a worn tool are presented and compared which shows... 

In this paper, the occurrence of various types of bifurcation including symmetry breaking, period-doubling (flip) and secondary Hopf (Neimark) bifurcations in milling process with tool-wear and process damping effects are investigated. An extended dynamic model of the milling process with tool flank wear, process damping and nonlinearities in regenerative chatter terms is presented. Closed form expressions for the nonlinear cutting forces are derived through their Fourier series components. Non-autonomous parametrically excited equations of the system with time delay terms are developed. The multiple-scale approach is used to construct analytical approximate solutions under primary... 

Chatter suppression is of great importance for achieving high precision and surface quality in machining processes. A single degree of freedom model of orthogonal turning process is used to set up the nonlinear delay differential equation of motion. Tool wear effect is considered as the contact force between the workpiece and tool flank surfaces. Uncertainties in parameters of dynamic model and machining conditions are included in the model. An adaptive control strategy is applied for chatter suppression in cutting process. The force provided by a piezoactuator is the control input of the system. Results of stability analysis and adaptive control for two distinct cases of sharp and worn... 

In this paper, internal resonance and nonlinear dynamics of regenerative chatter in milling process is investigated. An extended dynamic model of the peripheral milling process including both structural and cutting force nonlinearities is presented. Closed form expressions for the nonlinear cutting forces are derived through their Fourier series components. In the presence of the large vibration amplitudes, the loss of contact effect is included in this model. Using the multiple-scales approach, analytical approximate response of the delayed nonlinear system is obtained. Considering the internal resonance dynamics (i.e. mode coupling), the energy transfer between the coupled x-y modes is... 

Peripheral milling is extensively used in manufacturing industry. To achieve more material removal rate, high precision and surface quality and increase tool life, chatter vibration must be suppressed. In this paper, an extended dynamic model of the peripheral milling process including both the structural nonlinearity and nonlinear cutting forces is presented. Using the multiple-scale approach, as a perturbation technique, internal resonance of the milling process is investigated. Transfer of the energy between the coupled x-y modes is studied. According to results obtained, it is possible to adjust the rate at which the x-mode (or y-mode) decays by implementation of the internal resonance... 

Chatter suppression in machining processes results in more material removal rate, high precision and surface quality. In this paper, a single degree of freedom model of orthogonal turning process is used to set up the delay differential equation of motion with considering the tool wear effect as a contact force between the workpiece and tool flank surfaces. Sinusoidal spindle speed variations with different frequencies around the mean speed are modulated to disturb the regenerative mechanism. The optimal amplitudes of the speed modulations are found based on a genetic algorithm such that the input energy to the turning process is minimized. Results of the stability analysis and the... 

Chatter suppression in machining processes results in more material removal rate, high precision and surface quality. In this paper, two control strategies are developed to suppress chatter vibration in the turning process including a worn tool. In the first stage, a sinusoidal spindle speed variation around the mean speed is modulated to disturb the regenerative mechanism. The optimal amplitudes of the speed modulations are found based on a genetic algorithm such that the input energy to the turning process is minimized. In the second stage, to improve the response of the system which is associated with small ripples under the steady state condition, an adaptive controller is designed. In... 

Dynamic vibration absorbers are used as semi-active controllers to reduce the undesirable vibrations in many applications such as electrical transmission lines, helicopters, gas turbines, engines, bridges and etc. One type of these absorbers is tunable vibration absorber (TVA). In this paper, regenerative chatter in an orthogonal turning process is suppressed using a (TVA). It is shown that TVA can modify the frequency response function of the cutting tool so as to improve cutting stability in turning process. In addition, tool wear is an important factor which works as a positive damping and helps the chatter suppression beside exertion of the TVA. Finally, using the SIMULINK Toolbox of... 

Chatter suppression is of great importance in machining processes for achieving more material removal rate, high precision and surface quality. In this paper, an H∞ control algorithm is proposed for chatter suppression in the presence of tool wear and parameter uncertainties. Orthogonal turning process is modelled as a single degree of freedom model that includes the effect of tool flank wear. Control input of the system is the force provided by a piezo-actuator.The turning process model includes the uncertainties in cutting velocity, tool wear and dynamic model parameters. Using the μ-synthesis technique, an H∞ optimal controller is designed based on a DK-iteration algorithm. The... 

High-quality, high-production-rate machining operations are significantly hindered by the regenerative chatter. Therefore, chatter suppression is of great significance; and active control is one of the best ways to curb it. In this paper, the orthogonal turning process is modeled as a single-degree-of-freedom system that includes the effect of tool wear; and described through a delay differential equation (DDE). Based on the model, stability lobes diagrams are obtained by the trial and error. The actuator force is the input for the control system and the tool vibration is the output. A classical PID controller is designed to improve the stability of the process and curb the self-excited...