Abstract
The shortest possible tool stickout has been the traditional go-to approach with expectations of increased stability and productivity. However, experimental studies at Danish-Advanced-Manufacturing-Research-Center (DAMRC) have proven that for some tool stickout lengths, there exist local productivity optimums when utilizing the Stability Lobe Diagrams for chatter avoidance. This contradicts with traditional logic and the best practices taught to machinists. This paper explores the vibrational characteristics and behaviour of a milling system over the tool stickout length. The experimental investigation has been conducted by tap testing multiple endmills where the tool stickout length has been varied. For each length, the modal parameters have been recorded and mapped to visualize behavioural tendencies. The insights are conceptualized into a tool tuning approximation solution. It builds on an almost linear change in the natural frequencies when amending tool stickout, which results in changed positions of the Chatter-free Stability Lobes. Validation tests on the tool tuning approximation solution have shown varying success of the solution. This outlines the need for further research on the boundary conditions of the solution, to understand at which conditions the tool tuning approximation solution is applicable.
Highlights
Danish Advanced Manufacturing Research Center (DAMRC) have, for 10 years, worked with chatter avoidance [1]-[3] and machining stability [4]-[6] to improve productivity within the industry
The second tool-tuning strategy was uncovered by Schmitz et al [9]-[11] – “a dynamic absorber effect caused by modal interaction between substructures of the machine and the tool” [11][31]
The experimental data used for the analysis of the dynamic behaviour as the effect of the tool stickout are collected for multiple Vertical Milling Centers, multiple hydraulic tool holders, and multiple endmills
Summary
Exploration of the System Dynamics and its Impact o. The concept of the dynamic absorber effect is that individual modes of the machining system can interact by varying the length of the tool (or other machine components). At this interaction, an absorber effect is seen resulting in a generally stiffer system, which increases the chatter-free stability limit [31]. An absorber effect is seen resulting in a generally stiffer system, which increases the chatter-free stability limit [31]
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