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Dynamics of regenerative chatter and internal resonance in milling process with structural and cutting force nonlinearities

Moradi, H ; Sharif University of Technology | 2012

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  1. Type of Document: Article
  2. DOI: 10.1016/j.jsv.2012.03.003
  3. Publisher: Elsevier , 2012
  4. Abstract:
  5. 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 studied. The results show that during regenerative chatter under specific cutting conditions, one mode can decay. Furthermore, it is possible to adjust the rate at which the x-mode (or y-mode) decays by implementation of the internal resonance. Therefore, under both internal resonance and regenerative chatter conditions, it is possible to suppress the undesirable vibration of one mode (direction) in which accurate surface finish is required. Under the steady-state motion, jump phenomenon is investigated for the process with regenerative chatter under various cutting conditions. Moreover, the effects of structural and cutting force nonlinearities on the stability lobes diagram of the process are investigated
  6. Keywords:
  7. Closed-form expression ; Contact effect ; Cutting conditions ; Cutting forces ; Delayed nonlinear systems ; Extended dynamics ; Internal resonance ; Jump phenomenon ; Large vibrations ; Milling process ; Mode coupling ; Multiple-scales ; Peripheral milling ; Regenerative chatters ; Stability lobes ; Surface finishes ; Cutting ; Dynamics ; Energy transfer ; Fourier series ; Milling (machining) ; Resonance
  8. Source: Journal of Sound and Vibration ; Volume 331, Issue 16 , 2012 , Pages 3844-3865 ; 0022460X (ISSN)
  9. URL: http://www.sciencedirect.com/science/article/pii/S0022460X12001988