Sharif Digital Repository

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, the stability of delay differential equations (DDEs), describing self-excited vibrations in a micro-milling process, is investigated based on semi-discretization (SD) method. Due to the stubby geometry of micro-tools, the shear deformation and rotary inertia effects are considered for modeling the structure. The extended Hamilton's principle is used to derive a detailed dynamical model of the spinning micro-tool with the support of misalignment in which the gyroscopic effects cause coupling of equations. Considering the actual geometry of the micro-end mill, exact dynamic stiffness (DS) formulations are developed to investigate the tool's free vibration characteristics. The... 

In this paper, thermo mechanical finite element analysis of orthogonal machining process with a flexible tool is carried out to study the dynamic behaviour of the machining system and its stability against chatter vibration. By combining the simulation of chip formation in metal cutting with the dynamic phenomena leading to chatter development, the influence of various phenomena, including thermal effects resulting from friction and plastic deformations on the stability of the process are investigated. The novelty of this model is in its ability to evaluate the effect of temperature rise in the cutting zone on the stability of cutting process. Process stability is analyzed and compared for... 

Peripheral milling is extensively used in manufacturing processes, especially in aerospace industries where end mills are used for milling of wing parts and engine components. The generation of complex shapes with high quality for various types of materials is the main advantage of milling in contrast to other machining processes. During the milling process, the occurrence of self-excited vibrations or chatter may cause reduction in material removal rate (MRR), damage to the tool and spindle bearing or may result in poor dimensional accuracy and surface finish of the work-piece. In this paper, milling process is modeled as two degrees of freedom (2DOF) system in which the tool wear and... 

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,... 

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... 

During the milling process, self-excited vibration or chatter adversely affects tool life, surface quality and productivity rate. In this paper, nonlinear cutting forces of milling process are considered as a function of chip thickness with a complete third order polynomial (instead of the common linear dependency). An optimal control strategy is developed for chatter suppression of the system described through nonlinear delay differential equations. Counterbalance forces exerted by actuators in x and y directions are the control inputs. For optimal control problem, an appropriate performance index is defined such that the regenerative chatter is suppressed while control efforts are... 

In this paper, chatter instability of micro end mill tools is studied by taking into account the process damping effect. The actual geometry of the micro tool including shank, taper part and fluted section is considered in the analysis. Timoshenko beam theory is utilized to consider the shear deformation and rotary inertia effects due to short and thick beam-type structures of each parts of the micro tool. The extended Hamilton's Principle is used to formulate a detailed dynamical model of the rotating micro end mill. The governing equations are solved by assumed mode model expansion. An exact dynamic stiffness method is developed to investigate modal characteristics of the tool including... 

Chatter vibration is a major cause of limitations in increasing material removal rate in machining. Machining chatter is caused by the interaction between tool and work-piece. Various nonlinear phenomena in the machining process affect the occurrence of chatter. Finite element simulation of chip formation allows for incorporation of various factors in the chip formation process. It can therefore be used to simulate the occurrence of chatter in practical conditions and to predict the conditions that lead to stable cutting. In this paper, a one degree of freedom dynamic model of the cutting tool is used to simulate the interaction of machining dynamics with the thermo-mechanical chip formation... 

In this paper, a tunable vibration absorber set (TVAs) is designed to suppress regenerative chatter in milling process (as a semi-active controller). An extended dynamic model of the peripheral milling with closed form expressions for the nonlinear cutting forces is presented. The extension part of the cutting tool is modeled as an Euler-Bernoulli beam with in plane lateral vibrations (x-y directions). Tunable vibration absorbers in x-y directions are composed of mass, spring and dashpot elements. In the presence of regenerative chatter, coupled dynamics of the system (including the beam and x-y absorbers) is described through nonlinear delay differential equations. Using an optimal... 

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... 

Models for chatter prediction in machining often use a mechanistic force model that calculate the force as the product of a material dependent cutting constant and chip area. However, in reality, the forces are the result of complex interaction between the tool and the chip, and are affected by many factors. The effects of these complex, and often nonlinear, factors on the machining dynamics may only be included in chatter prediction if the chip formation process is simulated concurrently with simulation of the machining dynamics. In this paper, finite element simulation of the chip formation process is combined with simulation of chatter dynamics and the inter-relationship between the chip... 

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... 

This paper deals with the problem of chatter suppression in milling process in order to achieve higher precision, better surface quality and larger material removal rate (MRR). The peripheral milling process is modeled as a two degrees of freedom system and the effects of tool wear and process damping are considered. It is shown that when regenerative chatter develops, both tool wear and process damping act as stabilizing factors. For larger values of depth of cut and consequently higher MRR, tunable vibration absorbers (TVA) (in x-y directions) are designed to improve stability. An optimal algorithm is developed which determines the optimum values for absorbers' parameters. The effects of... 

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... 

A new 3-D nonlinear model of chatter vibration in turning process is presented in this paper. The workpiece is modeled as a rotating clamped-free beam which is excited by cutting forces. π-Buckingham theory is used to extract dimensionless parameters for this problem. Using these parameters, non-dimensional equations of motion are developed. An approximate analytical solution of the nonlinear problem is obtained. A study of the influence of different parameters on the stability results is developed. Using these results, turning velocity intervals for stable and unstable cuts are determined  

Proper operation of an engine requires accurate measurement or estimation of the engine's air charge provided to the control unit which reduces both the engine's fuel consumption and the emissions. The volumetric efficiency of the engine is a key variable in computations using the engine control unit to estimate the air charge using the speed-density equation. This paper presents a new approach for real-time estimation of the volumetric efficiency using the sliding-mode methodology. An adaptive sliding-mode observer is proposed which relies on measurements from the engine's conventional sensors. The observer is shown to estimate asymptotically the volumetric efficiency of the engine for... 

In this paper, a tunable vibration absorber (TVA) is designed to suppress regenerative chatter in milling of cantilever plates. In machining industry, the majority of work-piece materials or the interaction of work-piece/cutting tool causes the cutting forces to demonstrate nonlinear behavior. The application of TVA (as a semi-active controller) is investigated for the process with an extensive nonlinear model of cutting forces. Under regenerative chatter conditions, optimum values of the absorber position and its spring stiffness are found such that the plate vibration is minimized. For this purpose, an optimal algorithm is developed based on mode summation approach. Results are presented... 

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 is a limiting factor in machining systems with adverse effects for workpiece surface, tool and machine life and material removal rate. Proper modelling of this phenomenon requires that the dynamic characteristics of the machining system is known. It is common to obtain the dynamic of the system by modal tests in stationary condition. However, the vibration characteristics of a machine change between its operating and resting mode. The goal of this work is to study vibrations in boring using the vibrational characteristic in operational conditions using the operating deflection shape method. In this paper, vibration characteristics of the in the boring bar is obtained by both modal...