Development of automated impact system for modal analysis of micro-end mill

Abstract

The micro cutting tool used in micromilling process is highly susceptible to instability attributed to its low strength. A catastrophic failure of micro-end mill can occur if the chatter is not controlled during micromilling process, especially for micromilling of difficult-to-machine materials, like Ti and Ni alloys. Consequently, the control of chatter in micromilling process is necessary to manufacture the components with required dimensional and geometrical accuracy. Chatter can be avoided by selecting the stable process parameters from stability lobe diagram or by changing the process parameters during machining process by chatter onset identification. The both ways of chatter avoidance require the reliable identification of the modal parameters of the micro-end mill. Experimental modal analysis is most accurate method for identification of modal parameters owing to its ability of consideration of machine tool compliance. Hence, in the present work, automated impact system has been developed to impact the micro-end mill under both stationary and rotating conditions. The developed impact system has been found to be impacting the micro-end with maximum deviation of 2.6% in force amplitude due to repeated impacts. A maximum variation of 1.7% has been found in the natural frequency due to different impacts of the micro-end mill under both stationary and rotating conditions. The accurate estimation of frequency response function is expected to predict the stability of micromilling process with high reliability.