Skip to main content

2021 | OriginalPaper | Buchkapitel

Automated Upgraded Generalized Full-Discretization Method: Application to the Stability Study of a Thin-Walled Milling Process

verfasst von : Chigbogu Ozoegwu, Peter Eberhard

Erschienen in: Mechanical Sciences

Verlag: Springer Singapore

Aktivieren Sie unsere intelligente Suche um passende Fachinhalte oder Patente zu finden.

search-config
loading …

Abstract

A tensor-based general order full-discretization method which can be automated to preempt all manual case-by-case symbolic analyses associated with chatter stability identification is upgraded with the capacity for model order reduction of elastic thin-walled workpieces. The implemented method is then exploited for studying the sensitivity of the precision of stability lobes of a reduced elastic thin-walled workpiece to arbitrary variation of interpolation order of both the current and delayed regenerative chatter states. The studied system shows almost identical results for unidirectional and bidirectional models. It was further found that within the numerically stable interpolation orders which are usually from 0 to 9, stability lobes are mildly sensitive to the variation of the order of the current state but strongly sensitive to the variation of the order of the delayed state. Though no combination of orders of current and delayed states is seen to outperform the others in all spindle speed ranges, it is recommended to keep the order of the delayed state at 3 while the order of the current state is varied to get the best results. Error surfaces and time-domain simulations were instrumental in the deductions and discussions of results. The programmed method offers potential industrial benefit of making use of stability lobes for precise selection of productive chatter-free process parameters more user-friendly.

Sie haben noch keine Lizenz? Dann Informieren Sie sich jetzt über unsere Produkte:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

  • über 102.000 Bücher
  • über 537 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Finance + Banking
  • Management + Führung
  • Marketing + Vertrieb
  • Maschinenbau + Werkstoffe
  • Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

  • über 67.000 Bücher
  • über 390 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Maschinenbau + Werkstoffe




 

Jetzt Wissensvorsprung sichern!

Literatur
1.
Zurück zum Zitat Altinta, Y., Budak, E.: Analytical prediction of stability lobes in milling. CIRP Ann. Manuf. Technol. 44(1), 357–362 (1995)CrossRef Altinta, Y., Budak, E.: Analytical prediction of stability lobes in milling. CIRP Ann. Manuf. Technol. 44(1), 357–362 (1995)CrossRef
2.
Zurück zum Zitat Insperger, T., Stépán, G.: Stability of the milling process. Period. Polytechn. Mech. Eng. 44(1), 47–57 (2000) Insperger, T., Stépán, G.: Stability of the milling process. Period. Polytechn. Mech. Eng. 44(1), 47–57 (2000)
3.
Zurück zum Zitat Ding, Y., Zhu, L., Zhang, X., Ding, H.: Numerical integration method for prediction of milling stability. J. Manuf. Sci. Eng. 133(3), 1–9 (2011)CrossRef Ding, Y., Zhu, L., Zhang, X., Ding, H.: Numerical integration method for prediction of milling stability. J. Manuf. Sci. Eng. 133(3), 1–9 (2011)CrossRef
4.
Zurück zum Zitat Ozoegwu, C., Ofochebe, S., Omenyi, S.: A method of improving chatter-free conditions with combined-mode milling. J. Manuf. Process. 21, 1–13 (2016)CrossRef Ozoegwu, C., Ofochebe, S., Omenyi, S.: A method of improving chatter-free conditions with combined-mode milling. J. Manuf. Process. 21, 1–13 (2016)CrossRef
5.
Zurück zum Zitat Altintas, Y., Montgomery, D., Budak, E.: Dynamic peripheral milling of flexible structures. Precis. Eng. 13(3), 137–145 (1991) Altintas, Y., Montgomery, D., Budak, E.: Dynamic peripheral milling of flexible structures. Precis. Eng. 13(3), 137–145 (1991)
6.
Zurück zum Zitat Bravo, U., Altuzarra, O., López De Lacalle, L.N., Sánchez, J.A., Campa, F.J.: Stability limits of milling considering the flexibility of the workpiece and the machine. Int. J. Mach. Tools Manuf. 45(15), 1669–1680 (2005)CrossRef Bravo, U., Altuzarra, O., López De Lacalle, L.N., Sánchez, J.A., Campa, F.J.: Stability limits of milling considering the flexibility of the workpiece and the machine. Int. J. Mach. Tools Manuf. 45(15), 1669–1680 (2005)CrossRef
7.
Zurück zum Zitat Herranz, S., Campa, F.J., De Lacalle, L.N., Rivero, A., Lamikiz, A., Ukar, E., Sánchez, J.A., Bravo, U.: The milling of airframe components with low rigidity: a general approach to avoid static and dynamic problems. Proc. Inst. Mech. Eng. Part B: J. Eng. Manuf. 219(11), 789–801 (2005)CrossRef Herranz, S., Campa, F.J., De Lacalle, L.N., Rivero, A., Lamikiz, A., Ukar, E., Sánchez, J.A., Bravo, U.: The milling of airframe components with low rigidity: a general approach to avoid static and dynamic problems. Proc. Inst. Mech. Eng. Part B: J. Eng. Manuf. 219(11), 789–801 (2005)CrossRef
8.
Zurück zum Zitat Thevenot, V., Arnaud, L., Dessein, G., Cazenave-Larroche, G.: Integration of dynamic behaviour variations in the stability lobes method: 3D lobes construction and application to thin-walled structure milling. Int. J. Adv. Manuf. Technol. 27(7–8), 638–644 (2006)CrossRef Thevenot, V., Arnaud, L., Dessein, G., Cazenave-Larroche, G.: Integration of dynamic behaviour variations in the stability lobes method: 3D lobes construction and application to thin-walled structure milling. Int. J. Adv. Manuf. Technol. 27(7–8), 638–644 (2006)CrossRef
9.
Zurück zum Zitat Thevenot, V., Arnaud, L., Dessein, G., Cazenave-Larroche, G.: Influence of material removal on the dynamic behavior of thin-walled structures in peripheral milling. Mach. Sci. Technol. 10(3), 275–287 (2006)CrossRef Thevenot, V., Arnaud, L., Dessein, G., Cazenave-Larroche, G.: Influence of material removal on the dynamic behavior of thin-walled structures in peripheral milling. Mach. Sci. Technol. 10(3), 275–287 (2006)CrossRef
10.
Zurück zum Zitat Adetoro, O.B., Sim, W.M., Wen, P.H.: An improved prediction of stability lobes using nonlinear thin wall dynamics. J. Mater. Process. Technol. 210(6–7), 969–979 (2010)CrossRef Adetoro, O.B., Sim, W.M., Wen, P.H.: An improved prediction of stability lobes using nonlinear thin wall dynamics. J. Mater. Process. Technol. 210(6–7), 969–979 (2010)CrossRef
11.
Zurück zum Zitat Budak, E., Tunç, L.T., Alan, S., Özgüven, H.N.: Prediction of workpiece dynamics and its effects on chatter stability in milling. CIRP Ann. Manuf. Technol. 61(1), 339–342 (2012)CrossRef Budak, E., Tunç, L.T., Alan, S., Özgüven, H.N.: Prediction of workpiece dynamics and its effects on chatter stability in milling. CIRP Ann. Manuf. Technol. 61(1), 339–342 (2012)CrossRef
12.
Zurück zum Zitat Song, Q., Liu, Z., Wan, Y., Ju, G., Shi, J.: Application of Sherman-Morrison-Woodbury formulas in instantaneous dynamic of peripheral milling for thin-walled component. Int. J. Mech. Sci. 96–97, 79–90 (2015)CrossRef Song, Q., Liu, Z., Wan, Y., Ju, G., Shi, J.: Application of Sherman-Morrison-Woodbury formulas in instantaneous dynamic of peripheral milling for thin-walled component. Int. J. Mech. Sci. 96–97, 79–90 (2015)CrossRef
13.
Zurück zum Zitat Yang, Y., Zhang, W.H., Ma, Y.C., Wan, M.: Chatter prediction for the peripheral milling of thin-walled workpieces with curved surfaces. Int. J. Mach. Tools Manuf. 109, 36–48 (2016)CrossRef Yang, Y., Zhang, W.H., Ma, Y.C., Wan, M.: Chatter prediction for the peripheral milling of thin-walled workpieces with curved surfaces. Int. J. Mach. Tools Manuf. 109, 36–48 (2016)CrossRef
14.
Zurück zum Zitat Ahmadi, K.: Finite strip modeling of the varying dynamics of thin-walled pocket structures during machining. Int. J. Adv. Manuf. Technol. 89(9–12), 2691–2699 (2017)CrossRef Ahmadi, K.: Finite strip modeling of the varying dynamics of thin-walled pocket structures during machining. Int. J. Adv. Manuf. Technol. 89(9–12), 2691–2699 (2017)CrossRef
15.
Zurück zum Zitat Song, Q., Shi, J., Liu, Z., Wan, Y.: A time-space discretization method in milling stability prediction of thin-walled component. Int. J. Adv. Manuf. Technol. 89(9–12), 2675–2689 (2017)CrossRef Song, Q., Shi, J., Liu, Z., Wan, Y.: A time-space discretization method in milling stability prediction of thin-walled component. Int. J. Adv. Manuf. Technol. 89(9–12), 2675–2689 (2017)CrossRef
16.
Zurück zum Zitat Shi, J., Song, Q., Liu, Z., Ai, X.: A novel stability prediction approach for thin-walled component milling considering material removing process. Chin. J. Aeronaut. 30(5), 1789–1798 (2017)CrossRef Shi, J., Song, Q., Liu, Z., Ai, X.: A novel stability prediction approach for thin-walled component milling considering material removing process. Chin. J. Aeronaut. 30(5), 1789–1798 (2017)CrossRef
17.
Zurück zum Zitat Song, Q., Ai, X., Tang, W.: Prediction of simultaneous dynamic stability limit of time-variable parameters system in thin-walled workpiece high-speed milling processes. Int. J. Adv. Manuf. Technol. 55(9–12), 883–889 (2011)CrossRef Song, Q., Ai, X., Tang, W.: Prediction of simultaneous dynamic stability limit of time-variable parameters system in thin-walled workpiece high-speed milling processes. Int. J. Adv. Manuf. Technol. 55(9–12), 883–889 (2011)CrossRef
18.
Zurück zum Zitat Zhang, L., Gao, W., Zhang, D., Tian, Y.: Prediction of dynamic milling stability considering time variation of deflection and dynamic characteristics in thin-walled component milling process. Shock Vib. 2016, 1–14 (2016) Zhang, L., Gao, W., Zhang, D., Tian, Y.: Prediction of dynamic milling stability considering time variation of deflection and dynamic characteristics in thin-walled component milling process. Shock Vib. 2016, 1–14 (2016)
19.
Zurück zum Zitat Eksioglu, C., Kilic, Z.M., Altintas, Y.: Discrete-time prediction of chatter stability, cutting forces, and surface location errors in flexible milling systems. J. Manuf. Sci. Eng. 134(6), 1–13 (2012)CrossRef Eksioglu, C., Kilic, Z.M., Altintas, Y.: Discrete-time prediction of chatter stability, cutting forces, and surface location errors in flexible milling systems. J. Manuf. Sci. Eng. 134(6), 1–13 (2012)CrossRef
20.
Zurück zum Zitat Wan, M., Dang, X.B., Zhang, W.H., Yang, Y.: Optimization and improvement of stable processing condition by attaching additional masses for milling of thin-walled workpiece. Mech. Syst. Signal Process. 103, 196–215 (2018)CrossRef Wan, M., Dang, X.B., Zhang, W.H., Yang, Y.: Optimization and improvement of stable processing condition by attaching additional masses for milling of thin-walled workpiece. Mech. Syst. Signal Process. 103, 196–215 (2018)CrossRef
21.
Zurück zum Zitat Li, Z., Sun, Y., Guo, D.: Chatter prediction utilizing stability lobes with process damping in finish milling of titanium alloy thin-walled workpiece. Int. J. Adv. Manuf. Technol. 89(9–12), 2663–2674 (2017)CrossRef Li, Z., Sun, Y., Guo, D.: Chatter prediction utilizing stability lobes with process damping in finish milling of titanium alloy thin-walled workpiece. Int. J. Adv. Manuf. Technol. 89(9–12), 2663–2674 (2017)CrossRef
22.
Zurück zum Zitat Zhang, Z., Li, H., Liu, X., Zhang, W., Meng, G.: Chatter mitigation for the milling of thin-walled workpiece. Int. J. Mech. Sci. 138–139, 262–271 (2018)CrossRef Zhang, Z., Li, H., Liu, X., Zhang, W., Meng, G.: Chatter mitigation for the milling of thin-walled workpiece. Int. J. Mech. Sci. 138–139, 262–271 (2018)CrossRef
23.
Zurück zum Zitat Hamann, D., Eberhard, P.: Stability analysis of milling processes with varying workpiece dynamics. Multibody Syst. Dyn. 42(4), 383–396 (2018)MathSciNetCrossRef Hamann, D., Eberhard, P.: Stability analysis of milling processes with varying workpiece dynamics. Multibody Syst. Dyn. 42(4), 383–396 (2018)MathSciNetCrossRef
24.
Zurück zum Zitat Ma, Y.-C., Yang, Y., Wan, M., Zhang, W.-H., Dang, X.-B.: An efficient decomposition-condensation method for chatter prediction in milling large-scale thin-walled structures. Mech. Syst. Signal Process. 121, 58–76 (2019)CrossRef Ma, Y.-C., Yang, Y., Wan, M., Zhang, W.-H., Dang, X.-B.: An efficient decomposition-condensation method for chatter prediction in milling large-scale thin-walled structures. Mech. Syst. Signal Process. 121, 58–76 (2019)CrossRef
25.
Zurück zum Zitat Dong, X., Zhang, W.: Stability analysis in milling of the thin walled part considering multiple variables of manufacturing systems. Int. J. Adv. Manuf. Technol. 89(1–4), 515–527 (2017)CrossRef Dong, X., Zhang, W.: Stability analysis in milling of the thin walled part considering multiple variables of manufacturing systems. Int. J. Adv. Manuf. Technol. 89(1–4), 515–527 (2017)CrossRef
26.
Zurück zum Zitat Ozoegwu, C.G.: Polynomial tensor-based stability identification of milling process: application to reduced thin-walled workpiece. In: Fehr, J., Haasdonk, B. (eds.) IUTAM Symposium on Model Order Reduction of Coupled Systems, Stuttgart, Germany, 22–25 May 2018, vol. 36, ch. 15, pp. 209–220. Springer International Publishing, Stuttgart, Germany (2020) Ozoegwu, C.G.: Polynomial tensor-based stability identification of milling process: application to reduced thin-walled workpiece. In: Fehr, J., Haasdonk, B. (eds.) IUTAM Symposium on Model Order Reduction of Coupled Systems, Stuttgart, Germany, 22–25 May 2018, vol. 36, ch. 15, pp. 209–220. Springer International Publishing, Stuttgart, Germany (2020)
27.
Zurück zum Zitat Tang, A., Liu, Z.: Three-dimensional stability lobe and maximum material removal rate in end milling of thin-walled plate. Int. J. Adv. Manuf. Technol. 43(1–2), 33–39 (2009)CrossRef Tang, A., Liu, Z.: Three-dimensional stability lobe and maximum material removal rate in end milling of thin-walled plate. Int. J. Adv. Manuf. Technol. 43(1–2), 33–39 (2009)CrossRef
28.
Zurück zum Zitat Qu, S., Zhao, J., Wang, T.: Three-dimensional stability prediction and chatter analysis in milling of thin-walled plate. Int. J. Adv. Manuf. Technol. 86(5–8), 2291–2300 (2016)CrossRef Qu, S., Zhao, J., Wang, T.: Three-dimensional stability prediction and chatter analysis in milling of thin-walled plate. Int. J. Adv. Manuf. Technol. 86(5–8), 2291–2300 (2016)CrossRef
29.
Zurück zum Zitat Powałka, B., Jemielniak, K.: Stability analysis in milling of flexible parts based on operational modal analysis. CIRP J. Manuf. Sci. Technol. 9, 125–135 (2015)CrossRef Powałka, B., Jemielniak, K.: Stability analysis in milling of flexible parts based on operational modal analysis. CIRP J. Manuf. Sci. Technol. 9, 125–135 (2015)CrossRef
30.
Zurück zum Zitat Ozoegwu, C., Eberhard, P.: Tensor-based automatic arbitrary order computation of the full-discretization method for milling stability analysis. In: Altenbach, H., Irschik, H., Matveenko, V. (eds.) Contributions to Advanced Dynamics and Continuum Mechanics, ch. 11, pp. 179 – 205. Springer International Publishing (2019) Ozoegwu, C., Eberhard, P.: Tensor-based automatic arbitrary order computation of the full-discretization method for milling stability analysis. In: Altenbach, H., Irschik, H., Matveenko, V. (eds.) Contributions to Advanced Dynamics and Continuum Mechanics, ch. 11, pp. 179 – 205. Springer International Publishing (2019)
31.
Zurück zum Zitat Ozoegwu, C.G., Omenyi, S.N., Ofochebe, S.M.: Hyper-third order full-discretization methods in milling stability prediction. Int. J. Mach. Tools Manuf. 92, 1–9 (2015)CrossRef Ozoegwu, C.G., Omenyi, S.N., Ofochebe, S.M.: Hyper-third order full-discretization methods in milling stability prediction. Int. J. Mach. Tools Manuf. 92, 1–9 (2015)CrossRef
32.
Zurück zum Zitat Bayly, P.V., Mann, B.P., Peters, D.A., Schmitz, T.L., Stepan, G., Insperger, T.: Effects of radial immersion and cutting direction on chatter instability in end-milling. In: ASME International Mechanical Engineering Congress and Exposition, New Orleans, pp. 1–13 (2002) Bayly, P.V., Mann, B.P., Peters, D.A., Schmitz, T.L., Stepan, G., Insperger, T.: Effects of radial immersion and cutting direction on chatter instability in end-milling. In: ASME International Mechanical Engineering Congress and Exposition, New Orleans, pp. 1–13 (2002)
Metadaten
Titel
Automated Upgraded Generalized Full-Discretization Method: Application to the Stability Study of a Thin-Walled Milling Process
verfasst von
Chigbogu Ozoegwu
Peter Eberhard
Copyright-Jahr
2021
Verlag
Springer Singapore
DOI
https://doi.org/10.1007/978-981-15-5712-5_4

    Marktübersichten

    Die im Laufe eines Jahres in der „adhäsion“ veröffentlichten Marktübersichten helfen Anwendern verschiedenster Branchen, sich einen gezielten Überblick über Lieferantenangebote zu verschaffen.