Skip to main content
SpringerLink
Log in

Stability analysis of milling processes with varying workpiece dynamics

  • Published:
Multibody System Dynamics Aims and scope Submit manuscript

Abstract

An approach for the systematic choice of process parameters by observing the entire machining process in milling is presented. There is a varying workpiece dynamics due to the machining, wherefore a distinct change of stability characteristics is possible. The new contribution of this paper is an approach using parametric model order reduction in stability analysis. Both parametric model order reduction and stability analysis of time-delayed systems are topics of current research although their combination is hardly investigated. The approach is very efficient compared to full models or other ideas described in literature, like parametric model order reduction based on substructuring. Thus, the continuous representation of the varying workpiece dynamics enables stability analysis as well as time-domain simulations with reasonable computation times.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9

Similar content being viewed by others

References

  1. Tobias, S.A.: Machine-Tool Vibration. Blackie, London (1965)

    Google Scholar 

  2. Henninger, C., Eberhard, P.: Analysis of dynamic stability for milling processes with varying workpiece dynamics. Proc. Appl. Math. Mech. 8(1), 10367–10368 (2008)

    Article  Google Scholar 

  3. Fischer, A., Eberhard, P., Ambrósio, J.: Parametric flexible multibody model for material removal during turning. J. Comput. Nonlinear Dyn. 9(1), 011007 (2014)

    Article  Google Scholar 

  4. Panzer, H., Mohring, J., Eid, R., Lohmann, B.: Parametric model order reduction by matrix interpolation. at-Automatisierungstechnik 58(8), 475–484 (2010)

    Article  Google Scholar 

  5. Holzwarth, P., Baumann, M., Volzer, T., Iroz, I., Bestle, P., Fehr, J., Eberhard, P.: Software Morembs. Institute of Engineering and Computational Mechanics, University of Stuttgart, Stuttgart, Germany (2016)

  6. Munoa, J., Beudaert, X., Dombovari, Z., Altintas, Y., Budak, E., Brecher, C., Stépán, G.: Chatter suppression techniques in metal cutting. CIRP Ann. 65(2), 785–808 (2016)

    Article  Google Scholar 

  7. Kline, W.A., DeVor, R.E., Shareef, I.A.: The prediction of surface accuracy in end milling. J. Eng. Ind. 104(3), 272–278 (1982)

    Article  Google Scholar 

  8. Altintas, Y., Montgomery, D., Budak, E.: Dynamic peripheral milling of flexible structures. J. Eng. Ind. 114(2), 137–145 (1992)

    Google Scholar 

  9. Budak, E., Tunç, L.T., Alan, S., Özgüven, H.N.: Prediction of workpiece dynamics and its effects on chatter stability in milling. CIRP Ann. 61(1), 339–342 (2012)

    Article  Google Scholar 

  10. 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)

    Article  Google Scholar 

  11. Ewins, D.: Modal Testing: Theory, Practice, and Application. Research Studies Press, Letchworth (2000)

    Google Scholar 

  12. Baumann, M., Eberhard, P.: Interpolation-based parametric model order reduction for material removal in elastic multibody systems. Multibody Syst. Dyn. 39(1), 21–36 (2017)

    Article  MathSciNet  MATH  Google Scholar 

  13. Fischer, M., Eberhard, P.: Simulation of moving loads in elastic multibody systems with parametric model reduction techniques. Arch. Mech. Eng. 61(2), 209–226 (2014)

    Article  Google Scholar 

  14. Insperger, T., Stépán, G.: Semi-Discretization for Time-Delay Systems: Stability and Engineering Applications. Springer, New York (2011)

    Book  MATH  Google Scholar 

  15. Bayly, P.V., Halley, J.E., Mann, B.P., Davies, M.A.: Stability of interrupted cutting by temporal finite element analysis. J. Manuf. Sci. Eng. 125(2), 220–225 (2003)

    Article  Google Scholar 

  16. Khasawneh, F.A., Mann, B.P.: A spectral element approach for the stability of delay systems. Int. J. Numer. Methods Eng. 87(6), 566–592 (2011)

    Article  MathSciNet  MATH  Google Scholar 

  17. Hamann, D.: Aufbau einer Toolbox zur Analyse von periodisch zeitvarianten, totzeitbehafteten Systemen. Master thesis DIPL-MSC-222, Institute of Engineering and Computational Mechanics, University of Stuttgart (2015) (in German)

  18. Merdol, S.D., Altintas, Y.: Multi frequency solution of chatter stability for low immersion milling. J. Manuf. Sci. Eng. 126(3), 459–466 (2004)

    Article  Google Scholar 

  19. Henninger, C., Eberhard, P.: Improving the computational efficiency and accuracy of the semi-discretization method for periodic delay-differential equations. Eur. J. Mech. A, Solids 27(6), 975–985 (2008)

    Article  MATH  Google Scholar 

  20. Hamann, D., Eberhard, P.: Milling stability analysis with varying workpiece dynamics. In: Proceedings International Conference on Multibody System Dynamics, Montreal, Canada (2016)

    Google Scholar 

Download references

Acknowledgements

The authors would like to thank the German Research Foundation (DFG) for financial support of the project within the Cluster of Excellence in Simulation Technology (EXC 310/2) at the University of Stuttgart. In addition, the authors would like to thank Dr.-Ing. Achim Fischer and Dr.-Ing. Michael Baumann, both from our institute, for the cooperation in this research project, their preparation of many issues and many discussions during work. A previous version of this paper was presented at the IMSD conference 2016 in Montreal [20]. The authors want to thank the editors for inviting this extended and revised paper for the journal.

Author information

Authors and Affiliations

  1. Institute of Engineering and Computational Mechanics, University of Stuttgart, Stuttgart, Germany

    Dominik Hamann & Peter Eberhard

Authors
  1. Dominik Hamann
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Peter Eberhard
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Peter Eberhard.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Hamann, D., Eberhard, P. Stability analysis of milling processes with varying workpiece dynamics. Multibody Syst Dyn 42, 383–396 (2018). https://doi.org/10.1007/s11044-017-9604-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11044-017-9604-5

Keywords

Search

Navigation