Suppression of period doubling chetter in high-speed milling by spindle speed variation

Spindle speed variation is a well known technique to suppress regenerative machine tool vibra- tions, but it is usually considered to be effective only for low spindle speeds. In the current paper, spindle speed variation is applied to the high speed milling process, at the spindle speeds where the constant speed cutting results in period doubling chatter. The stability analysis of triangular and sinusoidal shape variations is made numerically with the semi-discretization method. It is shown that the milling process can be stabilized by increasing the amplitude of the spindle speed variation, while the frequency of the variation has no significant effect on the dynamic behaviour. The results are validated by experiments. Based on the analysis of the machined workpieces, it is shown that the surface roughness can also be decreased by the spindle speed variation technique

Influence d'une vitesse de rotation variable sur les vibrations d'usinage en UGV

Les opérations de fraisage à grande vitesse sont couramment limitées par les vibrations régénératives. Dans cet article, nous allons étudier une solution de réduction du phénomène de broutement, basée sur la variation de la vitesse de rotation de l’outil. Afin de quantifier les gains de productivité, deux modélisations différentes du fraisage dynamique ont été adaptées et confrontées : la simulation temporelle et la semi-discrétisation. La comparaison de ces deux méthodes a montré une bonne cohérence des résultats aussi bien à vitesse constante qu’à vitesse variable. Ces deux modélisations ont été validées expérimentalement à vitesse constante et variable. Les essais d’usinage à vitesse variable ont permis de mettre en évidence la différence entre la stabilité théorique et expérimentale

Simulation of low rigidity part machining applied to thin-walled structures

The aim of this study is to evaluate the modelling of machining vibrations of thin-walled aluminium work- pieces at high productivity rate. The use of numerical simulation is generally aimed at giving optimal cutting conditions for the precision and the surface finish needed. The proposed modelling includes all the ingredients needed for real productive machining of thin-walled parts. It has been tested with a specially designed machining test with high cutting engagement and taking into account all the phenomena involved in the dynamics of cutting. The system has been modelled using several simulation techni- ques. On the one hand, the milling process was modelled using a dynamic mechanistic model, with time domain simulation. On the other hand, the dynamic parameters of the system were obtained step by step by finite element analysis; thus the variation due to metal removal and the cutting edge position has been accurately taken into account. The results of the simulations were compared to those of the experiments; the discussion is based on the analysis of the cutting forces, the amplitude and the frequency of the vibrations evaluating the presence of chatter. The specific difficulties to perfect simulation of thin-walled workpiece chatter have been finely analysed

On the stability of high-speed milling with spindle speed variation

Spindle speed variation is a well-known technique to suppress regenerative machine tool vibrations, but it is usually considered to be effective only for low spindle speeds. In this paper, the effect of spindle speed variation is analyzed in the high-speed domain for spindle speeds corresponding to the first flip (period doubling) and to the first Hopf lobes. The optimal amplitudes and frequencies of the speed modulations are computed using the semidiscre- tization method. It is shown that period doubling chatter can effectively be suppressed by spindle speed variation, although, the technique is not effective for the quasiperiodic chatter above the Hopf lobe. The results are verified by cutting tests. Some special cases are also discussed where the practical behavior of the system differs from the predicted one in some ways. For these cases, it is pointed out that the concept of stability is understood on the scale of the principal period of the system—that is, the speed modulation period for variable spindle speed machining and the tooth passing period for constant spindle speed machining