Abstract
Increased stability in machining processes is highly desired by all machining industries when vibrations and specially chatter occur. This phenomenon is defined as a self-excited vibration that occurs due to the regeneration of waviness of the workpiece surface. In machining industry, the trend is to rely on the trial and error method or mere experience when deciding the machining spindle speeds, depths of cut and tool stick-outs, all of which are parameters directly related to chatter occurrence. Currently, the shortest possible tool stick-out is chosen by default, but literature has proven that longer stick-outs may bring some advantages when it comes to material removal rates. Aiming to prove this theory, this paper will discuss the influence of the tool stick-out on machining chatter occurrence. To that end, the effect of the tool stick-out on the modal parameters of the system, on the Stability Lobe Diagram (SLD) and on productivity will be analysed. Therefore, a number of Tap-Tests to different tool/tool-holder/stick-out combinations have been performed, in order to gather the data (FRFs and SLDs) where the analysis is based on. Last but not least, some machining tests have been conducted aiming to compare the theoretical chatter occurrence conditions, provided by the SLD, with the experimental ones. For that, two Al5083 workpieces have been slot milled under different cutting conditions, facilitating the unexpected results wherein the conclusions have been based upon.
Highlights
Machining involves any process where a workpiece is cut into a desired size and shape, by a sequence of processes
The trend is to rely on the trial and error method or mere experience when deciding the machining spindle speeds, depths of cut and tool stick-outs, all of which are parameters directly related to chatter occurrence
The shortest possible tool stick-out is chosen by default, but literature has proven that longer stick-outs may bring some advantages when it comes to material removal rates
Summary
Machining involves any process where a workpiece is cut into a desired size and shape, by a sequence of processes This material removal is a consequence of the existent relative motion between the tool and the workpiece, where a given amount of the workpiece’s material will be separated in the form of chip. Operators choose the shortest possible tool stick-out by default, but literature has proven that longer stick-outs may be more optimal regarding productivity. Aiming to prove this theory, this paper will discuss the influence of the tool stick-out on machining chatter occurrence during milling operations, from a modal parameters and productivity point of view
Sign-in/Register to view highlights & summary Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callDisclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
