Abstract
Cutting chatter is extremely harmful to the machining process, and it is of great significance to eliminate chatter through analyzing the stability of the machining process. In this work, the stability of the milling process with multiple delays is investigated. Considering the regeneration effect, the dynamics of the milling process with variable pitch cutter is modeled as periodic coefficients delayed differential equations (DDEs) with multiple delays. An adaptive variable-step numerical integration method (AVSNIM) considering the effect of the helix angle is developed firstly, which can discretize the cutting period accurately, thereby improving the calculation accuracy of the stability limit of the milling process. The accuracy and efficiency of the AVSNIM are verified through a benchmark milling model. Subsequently, a novel spindle speed-dependent discretization algorithm is proposed, which is combined with the AVSNIM to further reduce the calculation time of the stability lobes diagram (SLD). The simulation experiment results demonstrate that the proposed algorithm can effectively reduce the calculation time.
Highlights
Chatter is a self-excited vibration induced in the machining process which reduces the machining efficiency and surface quality, accelerates the tool wear and shortens the tool durability
The stability lobes diagram (SLD) is constructed over a 200 × 100-sized grid, the machining condition is down-milling and the simulation parameters are set as follows: the spindle speed Ω ranges from 2500 to 12,500 rpm and the axial depth of cut w ranges from 0 to 10 mm
This work focuses on the stability analysis of milling process with multiple delays
Summary
Chatter is a self-excited vibration induced in the machining process which reduces the machining efficiency and surface quality, accelerates the tool wear and shortens the tool durability. The variable-step method proposed in [13] can discretize the forced vibration intervals accurately, and the calculation result has high accuracy, the effect of the helix angle is not considered in the derivation process. An AVSNIM, considering the helix angle, and a novel spindle speed-dependent discretization algorithm, are developed and combined to analyze the stability of the milling process with multiple time delays. They are expected to obtain high accuracy and shorten the calculation time.
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