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Prediction of machining chatter based on FEM simulation of chip formation under dynamic conditions

Mahnama, M ; Sharif University of Technology | 2010

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  1. Type of Document: Article
  2. DOI: 10.1016/j.ijmachtools.2010.03.009
  3. Publisher: 2010
  4. Abstract:
  5. Machining chatter is an inherently nonlinear phenomenon that is affected by many parameters such as cutting conditions, tool geometry e.g., nose radius and clearance angle and frictional conditions at the tool/workpiece interface. Models for chatter prediction often ignore nonlinearities or introduce them through simple models for friction and geometry. In particular, the effect of chiptool interaction on the occurrence of chatter is not investigated thoroughly. This paper presents a novel approach for prediction of chatter vibration and for investigation of the effects of various conditions on the onset of chatter. This approach uses finite element simulation to investigate the inter-relationship between the chatter vibration and the chip formation process. Simulation of chip formation is combined with dynamic analysis of machine tool to determine the interaction between the two phenomena. Mesh adaptation technique is used to move the tool inside the workpiece to form the chip, while a flexible tool is used to allow the tool to vibrate under variable loading conditions. By repeating the simulations under various widths of cut, it is shown that the onset of chatter can be detected, and the simulation is able to realistically predict various phenomena observed in actual machining process such as variation of shear angle and the increase of stability at lower speeds known as process damping. The stability map obtained from simulations is compared with experimental data attained through orthogonal cutting tests. Reasonable agreement observed between the two sets of results demonstrates the effectiveness of the simulation approach
  6. Keywords:
  7. Chatter ; Chatter vibrations ; Chip formations ; Clearance angle ; Cutting conditions ; Dynamic condition ; Experimental data ; FEM simulations ; Finite element simulations ; Flexible tool ; Machining chatter ; Machining Process ; Mesh adaptation ; Non-linear phenomena ; Non-Linearity ; Nose radius ; Orthogonal cutting ; Shear angles ; Simple model ; Simulation approach ; Stability map ; Tool geometry ; Variable loading conditions ; Work pieces ; Cutting tools ; Dynamic analysis ; Forecasting ; Friction ; Machinery ; Machining ; Finite element method
  8. Source: International Journal of Machine Tools and Manufacture ; Volume 50, Issue 7 , July , 2010 , Pages 611-620 ; 08906955 (ISSN)
  9. URL: http://www.sciencedirect.com/science/article/pii/S0890695510000532