Mill chatter is a common phenomenon in the metal strip rolling process. Product defects caused by mill vibration were reported worldwide during last two decades, which is usually classified as torque vibration of the ...Mill chatter is a common phenomenon in the metal strip rolling process. Product defects caused by mill vibration were reported worldwide during last two decades, which is usually classified as torque vibration of the driving system with low frequencies and vertical vibration of the mill stand with comparative higher frequencies. The frequency range of the vertical vibration is wide (in general from more than 100 Hz to more than 1 000 Hz), and the vibration phenomena are very complex, even it is very difficult to determine the vibration causes, which is followed the name "ghost vibration". During a fieldwork to measure the vibration in high-speed rolling mills, a frequency modulation phenomenon was identified, which had not been reported in strip rolling community. This article makes a theoretical investigation to the newly encountered phenomenon in strip rolling process. According to an analysis of the mill roller bearings, the periodic change of stiffness of roller bearings at the fixed load orientation, together with the periodic change of the effective errors of the bearings, may cause amplitude and frequency modulation,based on the theories of Fourier series and Bessel function. The comparison between test results and theoretical analysis implies that the frequency modulation is caused by the effective errors of the mill roller bearings that have 12 ripples on the internal ring of the bearings.展开更多
In this paper, the instantaneous undeformed chip thickness is modeled to include the dynamic modulation caused by the tool vibration while the dynamic regenerative effects are taken into account. The numerical method ...In this paper, the instantaneous undeformed chip thickness is modeled to include the dynamic modulation caused by the tool vibration while the dynamic regenerative effects are taken into account. The numerical method is used to solve the differential equations goveming the dynamics of the milling system. Several chatter detection criteria are applied synthetically to the simulated signals and the stability diagram is obtained in time-domain. The simulation results in time-domain show a good agreement with the analytical prediction, which is validated by the cutting experiments. By simulating the chatter stability lobes in the time-domain and analyzing the influences of different spindle speeds on the vibration amplitudes of the tool under a Fixed chip-load condition, conclusions could be drawn as follows： In rough milling, higher machining efficiency can be achieved by selecting a spindle speed corresponding to the axial depth of cut in accordance with the simulated chatter stability lobes, and in Fmish milling, lower surface roughness can be achieved by selecting a spindle speed well beyond the resonant frequency of machining system.展开更多
T-slot milling is one of the most common milling processes in industry. Despite recent advances in machining technology, productivity of T-slot milling is usually limited due to the process limitations such as high cu...T-slot milling is one of the most common milling processes in industry. Despite recent advances in machining technology, productivity of T-slot milling is usually limited due to the process limitations such as high cutting forces and stability. If cutting conditions are not selected properly the process may result in the poor surface finish of the workpiece and the potential damage to the machine tool. Currently, the predication of chatter stability and determination of optimal cutting conditions based on the modeling of T-slot milling process is an effective way to improve the material removal rate（MRR） of a T-slot milling operation. Based on the geometrical model of the T-slot cutter, the dynamic cutting force model was presented in which the average directional cutting force coefficients were obtained by means of numerical approach, and leads to an analytical determination of stability lobes diagram（SLD） on the axial depth of cut. A new kind of SLD on the radial depth of cut was also created to satisfy the special requirement of T-slot milling. Thereafter, a dynamic simulation model of T-slot milling was implemented using Matlab software. In order to verify the effectiveness of the approach, the transfer functions of a typical cutting system in a vertical CNC machining center were measured in both feed and normal directions by an instrumented hammer and accelerators. Dynamic simulations were conducted to obtain the predicated SLD under specified cutting conditions with both the proposed model and CutPro~. Meanwhile, a set of cutting trials were conducted to reveal whether the cutting process under specified cutting conditions is stable or not. Both the simulation comparison and experimental verification demonstrated that the satisfactory coincidence between the simulated, the predicted and the experimental results. The chatter-free T-slot milling with higher MRR can be achieved under the cutting conditions determined according to the SLD simulation.展开更多
Modals of the machine/tool and machine/part system are the principal factors affecting the stability of a milling process. Based on the modeling of chatter stability of milling process,the influence of modal parameter...Modals of the machine/tool and machine/part system are the principal factors affecting the stability of a milling process. Based on the modeling of chatter stability of milling process,the influence of modal parameters on chatter stability lobes independently or jointly has been analyzed by simulation. Peak-to-valley specific value,lobe coefficient and the corresponding calculation formula have been put forward. General laws and steps of modal simplification for multimodality system have been summarized.展开更多
A chatter experiment of micro-miniature turn-milling was carried out in this paper. In or- der to reduce the effect that the natural frequencies of workpieces brought to the chatter experiments of micro-miniature turn...A chatter experiment of micro-miniature turn-milling was carried out in this paper. In or- der to reduce the effect that the natural frequencies of workpieces brought to the chatter experiments of micro-miniature turn-milling, both positive and negative cone-shape workpieces were used . The chatter frequency of micro-miniature turn-milling process was obtained by the sampling and analyzing systems. Then by applying excitation experiments to the workpiece system and tool system respec- tively, the natural frequencies of these two systems were obtained. By comparing chatter frequency of micro-miniature turn-milling process with the natural frequencies of workpiece system and tool system, we found that chatter frequency of micro-miniature turn-milUng was close to the natural fre- quency of the low stiffness vibration body in the machine tool system. The funding could be useful for optimizing the structure of machine-tool and designing the machining process.展开更多
A novel extended methodology for chatter suppression in milling process by applying external forced vibrations to the workpiece in two orthogonal directions which are the feed and cross-feed directions.Both the regene...A novel extended methodology for chatter suppression in milling process by applying external forced vibrations to the workpiece in two orthogonal directions which are the feed and cross-feed directions.Both the regenerative and forced chatter suppression during the milling process of flexible workpieces are investigated.Here,the workpiece is subject to a sinusoidal periodic force in the feed direction to disrupt the regenerative effect.Additionally,to minimize the forced chatter,the workpiece is subject to the periodic excitation force in cross-feed direction.This force is proportional to the magnitude of the estimated cutting force in cross-feed direction and has a phase opposite to the cutting force to minimize the vibration amplitudes.The effectiveness of the proposed method is evaluated numerically and experimentally,for the spindle speed located in both the local minima and local maxima of the stability lobe diagram.The numerical simulations indicate significant suppression effect in terms of vibration amplitudes,resulting in suppression of both the regenerative chatter and the forced chatter.Experiments were conducted by using a workpiece-mounted active stage composed of flexure hinges and driven by piezoelectric actuators.The experimental results agree qualitatively with the numerical simulations.The proposed method indicates a remarkable vibration reduction effect for both regenerative and forced chatters.展开更多
The paper probes into a probable condition that causes temper mill chatter from aspect of electromechanical coupling of complex electromechanical system, and mainly studies the effect of temper mill electrical driving...The paper probes into a probable condition that causes temper mill chatter from aspect of electromechanical coupling of complex electromechanical system, and mainly studies the effect of temper mill electrical driving system harmonic current on the main motion of temper mill set. Aiming at the electrical driving system of CM04 temper mill, the effect of harmonic current is analyzed and evaluated according to different load. Combining the features of CM04 temper mill′s structure and its working state, the paper discusses in every detail how the harmonic current in main circuit, which can be regarded as a disturbance via feedback control circuit , influences main motion of temper mill set.展开更多
Chatter vibrations are a major limitation for rough milling operations,leading to productivity reduction,low tool life and poor surface finish.It has been shown recently that the machine tool′s own drives can be used...Chatter vibrations are a major limitation for rough milling operations,leading to productivity reduction,low tool life and poor surface finish.It has been shown recently that the machine tool′s own drives can be used to increase the stability limit related to structural modes of the machine.To damp the low frequency modes,a new feedback loop is added to the classical position,velocity and current cascaded control.The objective of this study is to analyse the limitations of this new chatter suppression technique.Constraints related to the non-collocated control are first studied on a simplified three-mass model and then experimentally demonstrated on a three-axis horizontal milling centre.The industrial integration of the new control loop with sampling time constraints and limited drive′s bandwidth is analysed.After determining the appropriate conditions to use this chatter suppression technique,a cutting test demonstrates that the stability limit can be doubled in the low regions of the stability lobes.展开更多
A 2 DOF dynamic model of regenerative chatter model with state-dependent time delay is developed in milling processes. Regenerative effects, ＂ploughing＂ or ＂rubbing＂ effects between the flank of the cutting edge a...A 2 DOF dynamic model of regenerative chatter model with state-dependent time delay is developed in milling processes. Regenerative effects, ＂ploughing＂ or ＂rubbing＂ effects between the flank of the cutting edge and the machined surface, and feed effects are considered. It is shown that the regenerative delay is determined by the combination of the cutter rotation and the tool vibrations resulting in a state-dependent time delay. The governing equation is a delay-differential equation with state-dependent delay （SD-DDE）, as op- posed to the standard models with constant time delay. Based on Frechet derivative theory, the linearization of periodic state-dependent delay differential equation is also investigated. For a system with practical milling parameters, the incorporation of the state-dependent delay into the model does not essentially affect the linear stability properties of the system.展开更多
文摘Mill chatter is a common phenomenon in the metal strip rolling process. Product defects caused by mill vibration were reported worldwide during last two decades, which is usually classified as torque vibration of the driving system with low frequencies and vertical vibration of the mill stand with comparative higher frequencies. The frequency range of the vertical vibration is wide (in general from more than 100 Hz to more than 1 000 Hz), and the vibration phenomena are very complex, even it is very difficult to determine the vibration causes, which is followed the name "ghost vibration". During a fieldwork to measure the vibration in high-speed rolling mills, a frequency modulation phenomenon was identified, which had not been reported in strip rolling community. This article makes a theoretical investigation to the newly encountered phenomenon in strip rolling process. According to an analysis of the mill roller bearings, the periodic change of stiffness of roller bearings at the fixed load orientation, together with the periodic change of the effective errors of the bearings, may cause amplitude and frequency modulation,based on the theories of Fourier series and Bessel function. The comparison between test results and theoretical analysis implies that the frequency modulation is caused by the effective errors of the mill roller bearings that have 12 ripples on the internal ring of the bearings.
基金National Key Technologies R&D Program (2006BA103A16)Fundamental Research Project of COSTIND (K1203020507, B2120061326)
文摘In this paper, the instantaneous undeformed chip thickness is modeled to include the dynamic modulation caused by the tool vibration while the dynamic regenerative effects are taken into account. The numerical method is used to solve the differential equations goveming the dynamics of the milling system. Several chatter detection criteria are applied synthetically to the simulated signals and the stability diagram is obtained in time-domain. The simulation results in time-domain show a good agreement with the analytical prediction, which is validated by the cutting experiments. By simulating the chatter stability lobes in the time-domain and analyzing the influences of different spindle speeds on the vibration amplitudes of the tool under a Fixed chip-load condition, conclusions could be drawn as follows： In rough milling, higher machining efficiency can be achieved by selecting a spindle speed corresponding to the axial depth of cut in accordance with the simulated chatter stability lobes, and in Fmish milling, lower surface roughness can be achieved by selecting a spindle speed well beyond the resonant frequency of machining system.
基金supported by National Science and Technology Support Program of China (Grant No. 2006BAF01B09-03)the Research Fund for the Doctoral Program of Higher Education of China (Grant No. 200800060010)Hunan Provincial Educational Department Scientific Research Project of China (Grant No. 08D096)
文摘T-slot milling is one of the most common milling processes in industry. Despite recent advances in machining technology, productivity of T-slot milling is usually limited due to the process limitations such as high cutting forces and stability. If cutting conditions are not selected properly the process may result in the poor surface finish of the workpiece and the potential damage to the machine tool. Currently, the predication of chatter stability and determination of optimal cutting conditions based on the modeling of T-slot milling process is an effective way to improve the material removal rate（MRR） of a T-slot milling operation. Based on the geometrical model of the T-slot cutter, the dynamic cutting force model was presented in which the average directional cutting force coefficients were obtained by means of numerical approach, and leads to an analytical determination of stability lobes diagram（SLD） on the axial depth of cut. A new kind of SLD on the radial depth of cut was also created to satisfy the special requirement of T-slot milling. Thereafter, a dynamic simulation model of T-slot milling was implemented using Matlab software. In order to verify the effectiveness of the approach, the transfer functions of a typical cutting system in a vertical CNC machining center were measured in both feed and normal directions by an instrumented hammer and accelerators. Dynamic simulations were conducted to obtain the predicated SLD under specified cutting conditions with both the proposed model and CutPro~. Meanwhile, a set of cutting trials were conducted to reveal whether the cutting process under specified cutting conditions is stable or not. Both the simulation comparison and experimental verification demonstrated that the satisfactory coincidence between the simulated, the predicted and the experimental results. The chatter-free T-slot milling with higher MRR can be achieved under the cutting conditions determined according to the SLD simulation.
基金Supported by the Fundamental Research Project of COSTI ND(K1203020507)
文摘Modals of the machine/tool and machine/part system are the principal factors affecting the stability of a milling process. Based on the modeling of chatter stability of milling process,the influence of modal parameters on chatter stability lobes independently or jointly has been analyzed by simulation. Peak-to-valley specific value,lobe coefficient and the corresponding calculation formula have been put forward. General laws and steps of modal simplification for multimodality system have been summarized.
基金Supported by National Defense Basic Scientific Research Project(A092000000)High Quality CNC Machine Tool and BasicManufacturing Equipment Scientific Major Project(2012ZX04010-061)
文摘A chatter experiment of micro-miniature turn-milling was carried out in this paper. In or- der to reduce the effect that the natural frequencies of workpieces brought to the chatter experiments of micro-miniature turn-milling, both positive and negative cone-shape workpieces were used . The chatter frequency of micro-miniature turn-milling process was obtained by the sampling and analyzing systems. Then by applying excitation experiments to the workpiece system and tool system respec- tively, the natural frequencies of these two systems were obtained. By comparing chatter frequency of micro-miniature turn-milling process with the natural frequencies of workpiece system and tool system, we found that chatter frequency of micro-miniature turn-milUng was close to the natural fre- quency of the low stiffness vibration body in the machine tool system. The funding could be useful for optimizing the structure of machine-tool and designing the machining process.
文摘A novel extended methodology for chatter suppression in milling process by applying external forced vibrations to the workpiece in two orthogonal directions which are the feed and cross-feed directions.Both the regenerative and forced chatter suppression during the milling process of flexible workpieces are investigated.Here,the workpiece is subject to a sinusoidal periodic force in the feed direction to disrupt the regenerative effect.Additionally,to minimize the forced chatter,the workpiece is subject to the periodic excitation force in cross-feed direction.This force is proportional to the magnitude of the estimated cutting force in cross-feed direction and has a phase opposite to the cutting force to minimize the vibration amplitudes.The effectiveness of the proposed method is evaluated numerically and experimentally,for the spindle speed located in both the local minima and local maxima of the stability lobe diagram.The numerical simulations indicate significant suppression effect in terms of vibration amplitudes,resulting in suppression of both the regenerative chatter and the forced chatter.Experiments were conducted by using a workpiece-mounted active stage composed of flexure hinges and driven by piezoelectric actuators.The experimental results agree qualitatively with the numerical simulations.The proposed method indicates a remarkable vibration reduction effect for both regenerative and forced chatters.
文摘The paper probes into a probable condition that causes temper mill chatter from aspect of electromechanical coupling of complex electromechanical system, and mainly studies the effect of temper mill electrical driving system harmonic current on the main motion of temper mill set. Aiming at the electrical driving system of CM04 temper mill, the effect of harmonic current is analyzed and evaluated according to different load. Combining the features of CM04 temper mill′s structure and its working state, the paper discusses in every detail how the harmonic current in main circuit, which can be regarded as a disturbance via feedback control circuit , influences main motion of temper mill set.
文摘Chatter vibrations are a major limitation for rough milling operations,leading to productivity reduction,low tool life and poor surface finish.It has been shown recently that the machine tool′s own drives can be used to increase the stability limit related to structural modes of the machine.To damp the low frequency modes,a new feedback loop is added to the classical position,velocity and current cascaded control.The objective of this study is to analyse the limitations of this new chatter suppression technique.Constraints related to the non-collocated control are first studied on a simplified three-mass model and then experimentally demonstrated on a three-axis horizontal milling centre.The industrial integration of the new control loop with sampling time constraints and limited drive′s bandwidth is analysed.After determining the appropriate conditions to use this chatter suppression technique,a cutting test demonstrates that the stability limit can be doubled in the low regions of the stability lobes.
基金the National Natural Science Foundation of China (50435020,50705052,50575126)the Natural Science Foundation of Shandong Province (Y2007F41)
文摘A 2 DOF dynamic model of regenerative chatter model with state-dependent time delay is developed in milling processes. Regenerative effects, ＂ploughing＂ or ＂rubbing＂ effects between the flank of the cutting edge and the machined surface, and feed effects are considered. It is shown that the regenerative delay is determined by the combination of the cutter rotation and the tool vibrations resulting in a state-dependent time delay. The governing equation is a delay-differential equation with state-dependent delay （SD-DDE）, as op- posed to the standard models with constant time delay. Based on Frechet derivative theory, the linearization of periodic state-dependent delay differential equation is also investigated. For a system with practical milling parameters, the incorporation of the state-dependent delay into the model does not essentially affect the linear stability properties of the system.
