Abstract
To predict chatter stability and suppress chatter vibration, a chatter stability prediction method for the spindle-tool holder-tool system with interface contact characteristics is constructed. A five-DOF model is constructed to determine the spindle-bearing interface dynamic contact stiffness considering the coupling effect of spindle and bearing. A fractal multiscale tool holder-spindle interface dynamic stiffness model is proposed considering time-varying cutting force. The fractal dimensions and cutting force coefficient parameters are identified from the power spectrum experiments and cutting force tests. The cutting force is solved according to the milling stability model. Dynamic model of the spindle-tool holder-tool system is found by the finite element method. Based on extended Floquet theory, chatter stability of the spindle system is studied. Effect of interface parameters, radial cutting depth, and feed rate on milling stability is researched. Milling force tests and milling stability tests are performed in order to verify the reliability of the method. Results find that the increase of front bearing preload and spindle-tool holder’s interference fit are effective to improve the milling stability. The optimal feed rate and the critical radial cutting depth are found. The model proposed in this paper can be used as an instruction for predicting and suppressing the chatter vibration and optimizing cutting parameters and also is helpful for designing the spindle-tool holder-tool system.
Highlights
Stable cutting is the most important condition for highspeed cutting
Because the displacements Xj are varied when the spindle-bearing system is running, dynamic contact stiffness between spindle and ball bearing interface can be solved by equation (3)
Milling force coefficients can be measured by milling experiment
Summary
Stable cutting is the most important condition for highspeed cutting. in actual machine processing, chatter vibration often occurs, which indicates that severe vibration exists. Contact stiffness between the spindle and the tool holder was experimentally studied by many researchers. E results found that cutting force had great effect on stiffness of spindle-tool holder. To calculate the contact properties of tool holder interface, analytical model of cutting force should be constructed. A model to suppress chatter stability through implementing spindle-tool holder vibration modes was presented by FRF modification [13]. E chatter stability prediction model for spindle-tool holder system was proposed, in which dynamic parameters of the system were achieved by modal identification test [14]. Deep research should be done to predict chatter stability according to the interface contact characteristics. Effect of contact interface parameters, radial cutting depth, and feed rate on milling stability is researched; the results were experimentally verified by comparison with the cutting experiment. Effect of contact interface parameters, radial cutting depth, and feed rate on milling stability is researched; the results were experimentally verified by comparison with the cutting experiment. e method in this paper is helpful for predicting, suppressing chatter vibration of spindle system in the design process
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