Chatter Vibration Research Articles

Co-Kriging model-based multi-fidelity regression for refining milling stability predictions of variable tool overhang length using limited experimental data

Determining chatter-free machining parameters is critical in process planning since chatter vibrations significantly affect machining quality and production efficiency. Stability lobe diagram is essential in selecting chatter-free machining parameters, but its predictions confront challenges in both theoretical accuracy and experimental efficiency. To address this, the Co-Kriging modelling is introduced to predict the tool overhang length-dependent stability limits with limited experiments. First, tool tip dynamics and cutting force coefficients of a source overhang length are roughly identified to obtain sufficient low-fidelity (LF) theoretical stability limits. The entropy-based sampling and affine transformation are used to sequentially obtain high-fidelity (HF) experimental stability limits and update LF stability limits. HF and updated LF datasets are combined to train a multi-fidelity (MF) Co-Kriging model. For a target overhang length, MF stability limits of the source overhang length serve as LF data, and a minimum mean absolute percentage error (MAPE)-based sampling guides the acquisition of HF stability limits. Combining HF data and LF data processed by affine transformation to train a target Co-Kriging model. Case studies reveal that the proposed method exhibits lower MAPE values and significantly outperforms other comparison methods in predicting experimental stability limits, particularly when confronted with limited experimental data.

Optimal milling cutter helix selection for period doubling chatter suppression

In high speed milling, interrupted cutting conditions can lead to period doubling chatter vibrations. While many studies have already confirmed that the use of helical tools can effectively shrink or remove these regions of unstable cutting, none of them has provided clear guidance to select the minimum helix that completely cancels the period doubling lobes. This study addresses this gap by introducing a novel analytical formula for a critical tool helix pitch: if the helix pitch is below the critical flip depth of cut of the straight helix cutter multiplied by π, the flip lobes will totally vanish. This rule is not only valuable for chatter-free process planning purposes, but it also establishes exact limit below which the fast and simple zeroth order stability algorithm can provide exact stability boundaries for helical tools. The effectiveness of the formula is numerically corroborated over three different milling scenarios: thin wall milling, slender tool and machine tool structure chatter cases. Finally, the findings are validated through experimental cutting tests.

Real-Time Milling Chatter Detection and Control with Axis Encoder Feedback and Spindle Speed Manipulation

This paper introduces a complete real-time algorithm, where the chatter is detected and eliminated by spindle speed manipulation via the chatter energy feedback calculated from the axis encoder measurement. The proposed method does not require profound knowledge of the machining dynamics; instead, the entire algorithm exploits the fact that milling vibrations consist of forced vibrations at spindle speed harmonics and chatter vibrations that are close to one of the natural modes, with sidebands which are spread at the multiples of spindle speed frequency above and below the chatter frequency. The developed algorithm is able to identify the amplitude, phase and frequency of all the harmonics constituting the periodic forced and chatter vibrations. The key challenge is to select dominant chatter frequencies for the calculation of a robust and accurate chatter energy ratio feedback; this is achieved by utilizing the frequency estimation variance of EKF as a novel chatter indicator. Based on the chatter energy ratio feedback, the controller overrides the spindle speed in order to suppress the chatter energy below a particular threshold value. The varying spindle speed challenge is handled by updating the state transition matrices of the Kalman filters and real-time calculation of the band-pass filter coefficients, based on the derived discrete time transfer functions. The developed algorithm is tested on a Deckel FP5cc CNC which is in-house retrofitted and has a PC-based controller for the real-time application of the proposed algorithm. It is shown that the real-time chatter frequency and amplitude estimates are compatible with off-line FFT analysis, and chatter can be successfully eliminated by energy feedback.

Tool Path Strategies for Efficient Milling of Thin-Wall Features

The milling of thin-wall geometries has been a challenge due to inherent chatter vibrations and workpiece deflections. Moreover, tool path generation strategies in CAD-CAM systems are not able to fully address all such concerns. The objective of this study is to demonstrate potential 5-axis milling tool path strategies, which do not exist in the conventional tool path generation. The demonstration is performed for increased efficiency in milling of thin-wall features considering the main limitation of chatter. The effects of varying workpiece dynamics on milling stability are shown in case studies through simulations and cutting experiments. Based on the simulation results, tool path strategies are developed. The effect of tool path generation and the relation to parameter selection are highlighted. Most of the discussion relies on previously reported experimental results. The results showed that by tailoring the tool path considering the concerns and limitations associated with thin-wall part structure and geometry, it is possible to increase productivity by at least two folds.

Cutting state recognition of spiral bevel gear face hobbing

Abstract To investigate the issue of chatter vibration during the face hobbing process of spiral bevel gears, this study conducted experiments on the YKA2260 gear hobbing machine, collecting 142 sets of vibration acceleration signals. The optimal combination for wavelet threshold denoising was determined based on the signal-to-noise ratio (SNR), and preprocessing of the raw signals was performed. Utilizing wavelet packet decomposition, the energy entropy of wavelet packet coefficients was extracted as feature values. A recognition model for the cutting state during the face hobbing process of spiral bevel gears was established using a Support Vector Machine, achieving a recognition accuracy of up to 98.0769%. Furthermore, the model’s high recognition accuracy for small training samples in engineering applications was validated.

Dynamic modeling and analysis on rigid-flexible coupling between vertical chatter and transverse bending vibration in process of cold rolling

Dynamic modeling and analysis on rigid-flexible coupling between vertical chatter and transverse bending vibration in process of cold rolling

An effective investigation of chatter prediction system on Al6061 alloy in an end milling process

Visual examination of the surface topography, in conjunction with the other sensors, may confirm the existence of chatter. Online chatter detection during real machining operations is possible with the use of sensors, and the presence of noise in their output and restricted bandwidth are the major drawbacks of these sensors. Productivity drops and manufacturing costs go up when there is a lot of chatter in the machining process. In the present paper, an integrated spindle tool system is modeled using finite element method with Timoshenko beam theory including rotational and shear deformation effects. To maximize the average stable depth of cut in an end milling process while simultaneously minimizing the chatter vibration levels, real time and offline strategies have been investigated. Machining experiments performed on Al6061-alloy specimens provide an empirical confirmation of the stability boundaries. The surface topography methods such as scanning electron microscope (SEM) and optical microscope images along with vibration levels are considered, to identify chatter marks under various machining conditions, which helps to assure cutting process stability. Stability lobe diagrams are plotted with these derived conditions and observed at an incremental level in the axial depths of the cut. The methodology shown in this paper improves the machining stability of the end milling with the reduction in the tool tip vibrations.

Analytical and numerical optimization of broaching tool tooth distribution

This paper presents a detailed mathematical analysis of the effect of tooth distribution on the stability of broaching operations. Analytic and numeric techniques are employed to analyse a simplified one-degree-of-freedom mechanical model of variable pitch broaching, to assess its stability, and to find the optimal tooth distances maximizing robustness against harmful self-excited chatter vibrations. A novel modelling approach, considering a theoretical infinitely long broaching tool, draws parallels with variable pitch milling, and analytic formulas for tuning milling cutters are extended to broaching tools. For a further increase of robustness, and to take feasibility constraints into account, a goal function based on the semi-discretization and spectral collocation techniques is implemented in a direct numeric optimisation framework. A new, detailed derivation of the corresponding parameter gradients is presented to enable the use of gradient descent techniques. Since broaching is inherently a time-limited process, optimal parameters found in this manner are then validated via time domain simulations to show the desirable transient behaviours achievable by this ideal tuning of the tool geometry.

Chatter Stability of Orthogonal Turn-Milling Process in Frequency and Discrete-Time Domains

Abstract As the industry seeks better quality and efficiency, multitasking machine tools are becoming increasingly popular owing to their ability to create complex parts in one setup. Turn-milling, a type of multi-axis machining, combines milling and turning processes to remove material through simultaneous rotations of the cutter and workpiece with the translational feed of the tool. While turn-milling can be advantageous for large parts made of hard-to-cut materials, it also offers challenges in terms of surface form errors and process stability. Because tool eccentricity and workpiece rotation lead to more complexity in process mechanics and dynamics, traditional milling stability models cannot predict the stability of turn-milling processes. This study presents a mathematical model based on process mechanics and dynamics by incorporating the unique characteristics of the orthogonal turn-milling process to avoid self-excited chatter vibrations. A novel approach was employed to model time-varying delays considering the simultaneous rotation of the tool and workpiece. Stability analysis of the system was performed in both the discrete-time and frequency domains. The effects of eccentricity and workpiece speed on stability diagrams were demonstrated and validated through experiments. The results show that the tool eccentricity and workpiece speed alter the engagement geometry and delay in the regeneration mechanism, respectively, leading to significant stability diagram alterations. The proposed approach offers a comprehensive framework for the stability of orthogonal turn-milling and guidance for the selection of process conditions to achieve stable cuts with enhanced productivity.

Inner Modulation Controlled Process for Suppression of Chatter Vibration in Double Inserts Turning

A novel cutting manner is presented to control regenerative chatter vibration in double inserts cutting, in which the forward and the backward inserts cut workpiece simultaneously with phase difference in the modulation of finished surface. In double inserts cutting, the forward insert is clamped above the backward insert. Both the inserts are positioned symmetrically with a height offset with respect to the workpiece rotation center. The forward insert mainly removes the material; while the backward insert cuts a part of the inner modulation to lose the regular excitation. The exciting force is also reduced with the cutting thickness of the forward insert after a workpiece revolution. Because the theoretical position offset of the inserts in the feed direction is small, the side cutting edges of inserts are aligned in the same position. The process parameters are determined by estimating the removal volume of the backward insert with the phase shift. The range of the cutting speed and the height offset are given by the frequency of the chatter vibration, which is nearly the same as the natural frequency of the workpiece in single degree of freedom. The proposed cutting manner is validated using comparison between the single insert and double inserts cuttings.

Special Issue on Advanced Metal Cutting Technologies

Cutting technologies are utilized in many industrial sectors, such as automobile, aircraft, and medical-device manufacturing as well as dies and molds. Thus, the requirements for higher geometric accuracy, better surface integrity, and longer component service lifetimes have substantially increased. In addition, maintaining high machining efficiency while simultaneously reducing power consumption and CO2 emissions during machining is important for sustainable development. This special issue features 11 papers on the most recent advances in cutting technologies for metals and composite materials. - Reverse finishing characteristics of drilling surfaces - Machining error simulation for end milling - Visualization of cutting phenomena using a single-crystal diamond tool - Milling of TiB2 particle-reinforced high-modulus steel - Electrodischarge-assisted turning of carbon fiber-reinforced polymers - Suppression of chatter vibration during double-insert turning - Prediction of surface roughness components during turning - Microtome blades for high-precision tissue sectioning - Boiling of coolant near the cutting edge in high-speed machining - Residual stress during drilling of aluminum alloy - Effect of strain hardening on burr control during drilling This issue provides an understanding of recent developments in cutting technologies, aiming to inspire further research in this field. We deeply appreciate the careful work of all the authors and thank the reviewers for their diligent efforts.

Study on Temporary Unloading for Chatter Vibration Suppression Using Fixed Superabrasive Polishing Stone with Five-Joint Closed-Link Small Robot and Voice Coil Motor Thrust Control

In this study, an existing superfinishing method used for polishing glass surfaces was refined using a five-joint closed-link compact robot with fixed abrasive grains. In previous studies, a voice coil motor was used to control the constant-pressure pressing force while maintaining the polishing force for a relatively short period. However, maintaining the polishing force for long periods is imperative for achieving a high-quality polished surface. Thus, in this study, a strain gauge load cell was adopted in addition to a conventional piezoelectric force sensor to maintain the polishing force for a long period. First, the amounts of DC drift of the piezoelectric force sensor and strain gauge type load cell were compared to confirm the necessity of signal processing as well as the compatibility of long-term force measurement and high-frequency vibration measurement by application. Further, a method was proposed in which the change in the pressing force was recorded from the connected sensor; when the pressing force fluctuated, chatter vibrations were determined to occur, and the pressing force was temporarily set to 0 N. This method could obtain a better polished surface than the proportional-integral-differential (PID) control, which simply controls the pressing force at a constant value. Finally, chatter vibrations could be determined by detecting high-frequency sounds using a sound level meter. Notably, a finely polished surface could be obtained.

Special Issue on Abrasive Technology for High-Precision and High-Efficiency Machining of High-Performance Materials

The demand for high-precision and high-efficient machining of high-performance materials and components has increased in various industries such as optical, automotive, communication, life sciences, and medical sciences. Certain difficult-to-machine materials can be reliably machined using deterministic precision cutting processes. However, hard and brittle materials such as ceramics, carbides, hardened steel molds, glassy materials, or semiconductor materials, require precision abrasive technologies with super abrasives like diamond, cBN, or new tool materials for machining. However, machining high-precision components and their molds/dies using abrasive processes is considerably more difficult due to their complex and non-deterministic nature and textured surfaces. Furthermore, high-energy processes such as laser technology can assist abrasive technologies in ensuring higher precision and efficiency. Precision grinding and polishing processes are primarily used to generate high-quality and functional components, typically made of difficult-to-machine materials. Thus, the surface quality achievable by precision grinding and polishing processes becomes more important for reducing machining time and costs. This special issue features 10 papers on the most recent advances in precision abrasive technologies. These papers cover the following topics: - Ultrasonic grinding of micro holes using cemented WC tools - Drilling holes in CFRP aircraft using cBN electroplated ball end mill - In situ evaluation of drill wear using tool images - Grinding belt based on modified information entropy - Radial directional vibration-assisted grinding of Al2O3 ceramics - Chatter vibration suppression using fixed superabrasive polishing stone - Free abrasive finishing of internal channels with different cross-sectional geometries - High-quality machining of cemented carbide using PCD ball end mills - Fixed-abrasive machining with magnetic brush for Ti-6Al-4V ELI alloy - High-efficient polishing of polymer surfaces using catalyst-referred etching This issue will provide an understanding of the recent developments in abrasive technologies, leading to further research. We deeply appreciate the careful work of all the authors, and we thank the reviewers for their incisive efforts.

Dynamic Modeling for Chatter Analysis in Micro-Milling by Integrating Effects of Centrifugal Force, Gyroscopic Moment, and Tool Runout.

During micro-milling, regenerative chatter will decrease the machining accuracy, destabilize the micro-milling process, shorten the life of the micro-mill, and increase machining failures. Establishing a mathematical model of chatter vibration is essential to suppressing the adverse impact of chatter. The mathematical model must include the dynamic motions of the cutting system with the spindle-holder-tool assembly and tool runout. In this study, an integrated model was developed by considering the centrifugal force induced by rotational speeds, the gyroscopic effect introduced by high speeds, and the tool runout caused by uncertain factors. The tool-tip frequency-response functions (FRFs) obtained by theoretical calculations and the results predicted by simulation experiments were compared to verify the developed model. And stability lobe diagrams (SLDs) and time-domain responses are depicted and analyzed. Furthermore, experiments on tool-tip FRFs and micro-milling were conducted. The results validate the effectiveness of the integrated model, which can calculate the tool-tip FRFs, SLDs, and time responses to analyze chatter stability by considering the centrifugal force, gyroscopic effect, and tool runout.

Chatter vibration of workpiece deformation type in cutting thin-walled cylindrical workpiece (Prediction of chatter vibration generation using open-loop transfer function)

Chatter vibration of workpiece deformation type in cutting thin-walled cylindrical workpiece (Prediction of chatter vibration generation using open-loop transfer function)

Milling Stability Prediction under Multi-effect Synergy

During the milling process, chatter vibration is prone to occur when the spindle, tool, and workpiece interact with each other under certain parameters, which seriously affects machining efficiency and reduces machining quality. Therefore, it is necessary to study the mechanism and influencing factors of chatter vibration, predict the stability of the milling system through a multi-effect synergistic dynamic model, and obtain the machining parameters of stable milling through analysis. Based on the traditional milling model, this article considered the regeneration effect, process damping effect, and modal coupling effect, and also considered the friction effect of the front cutting surface for friction-induced chatter, to make the model’s prediction range more accurate. Then, a milling dynamic model was established combining multiple effects, and its stability lobe diagrams were solved by the full-discretization method. The accuracy of the model was verified through milling stability experiments. The experimental results are basically consistent with the predicted stability lobe diagrams, indicating that the milling stability prediction model considering multi-factor coupling of the milling model is correct. Finally, the influence of various effects on milling stability was analyzed, with a focus on the influence of friction effects.

Influence of Tools and Cutting Strategy on Milling Conditions and Quality of Horizontal Thin-Wall Structures of Titanium Alloy Ti6Al4V.

Titanium and nickel alloys are used in the creation of components exposed to harsh and variable operating conditions. Such components include thin-walled structures with a variety of shapes created using milling. The driving factors behind the use of thin-walled components include the desire to reduce the weight of the structures and reduce the costs, which can sometimes be achieved by reducing the machining time. This situation necessitates, among other things, the use of new machining methods and/or better machining parameters. The available tools, geometrically designed for different strategies, allow working with similar and improved cutting parameters (increased cutting speeds or higher feed rates) without jeopardizing the necessary quality of finished products. This approach causes undesirable phenomena, such as the appearance of vibrations during machining, which adversely affect the surface quality including the surface roughness. A search is underway for cutting parameters that will minimize the vibration while meeting the quality requirements. Therefore, researching and evaluating the impact of cutting conditions are justified and common in scientific studies. In our work, we have focused on the quality characteristics of horizontal thin-walled structures from Ti6Al4V titanium alloys obtained in the milling process. Our experiments were conducted under controlled cutting conditions at a constant value of the material removal rate (2.03 cm3⁄min), while an increased value of the cut layer was used and tested for use in finishing machining. We used three different cutting tools, namely, one for general purpose machining, one for high-performance machining, and one for high-speed machining. Two strategies were adopted: adaptive face milling and adaptive cylindrical milling. The output quantities included the results of acceleration vibration amplitudes, and selected surface topography parameters of waviness (Wa and Wz) and roughness (Ra and Rz). The lowest values of the pertinent quantities were found for a sample machined with a high-performance tool using adaptive face milling. Surfaces typical of chatter vibrations were seen for all samples.

Improved STFT analysis using time-frequency masking for chatter detection in the milling process

In the field of machining, the purposeful increase in cutting depth and rotation speed can potentially cause chatter vibration. Chatter lowers surface quality, tool and spindle life, and produces excessive noise, which limits the productivity of the machining process. In this paper, an improved Short-Time Fourier Transform (STFT) involving time–frequency masking and adaptive thresholding is proposed. Initially, hammering tests were undertaken to ascertain the inherent natural frequency of the cutting system. Subsequently, milling tests were conducted across varied conditions utilizing an accelerometer sensor and a microphone (capturing sound signals) to acquire the requisite experimental data. A 3-level Variational Mode Decomposition (VMD) was used for pre-processing due to its inherentcapabilities for noise reduction. The chatter threshold is established by averaging the total intrinsic mode function (IMF) energy levels that have been selected. To demonstrate the efficacy of the proposed method, root mean square (RMS) and skewness were calculated as chatter indicators. The improved STFT time–frequency representation (TFR) was compared to the conventional TFR. Notably, both indicators demonstrate effectiveness and chatter sensitivity, while the improved STFT offers greater time–frequency resolution than its conventional counterpart and can be successfully used for monitoring the milling process.

FUNDAMENTAL ANALYSIS ON THE DYNAMIC BEHAVIOR OF TOOLS WITH STRUCTURED FUNCTIONAL SURFACES IN CUTTING OPERATIONS

The productivity of machining processes is often limited by the occurrence of dynamic effects. The investigated approach intends to counteract tool deflections, and thus to damp and disrupt chatter vibrations by using milling tools with defined functional structures on the flank faces at the frontal cutting edges. For the fundamental investigation of the interactions between structural geometric properties and the tool-workpiece interaction, the engagement situation was geometrically evaluated on a highly abstracted level. Subsequently, hypotheses derived from this were validated experimentally in analogy tests with linear cutting motion. In these cutting experiments, dynamic deflections were induced by an external excitation of the specifically compliant modular tool system. Finally, the technologically most relevant structure variants were applied to milling tools and evaluated with regard to their dynamic behavior. This investigation was preceded by a simulation-based analysis of the material removal on the frontal flank face as a function of the process configuration, which is characterized by multiple intersecting cuts in milling processes. By specifically optimizing and coordinating the structure design and the process configuration, an increase in process stability and thus productivity of at least 100% could be achieved.

ROBOT ASSISTED STABILIZATION FOR FLEXIBLE WORKPIECES SUBJECTED TO HIGHLY INTERRUPTED CUTTING

In many facets of industry, slender workpieces are formed by means of milling processes. These workpieces are especially prone to experience harmful chatter vibrations, which limits quality and productivity. In this paper, a novel solution is proposed where a robotic arm is used to support the workpiece, improving its modal properties and reducing the occurrence of chatter. The paper presents some numerical, analytical and limited experimental results for improving the material removal rate using the robot assisted milling method for low radial immersion processes, such as finishing operations.