The chatter phenomenon can severely limit the power available for milling. The stability lobe diagram (SLD) is a very fast and simple method to predict the chatter free zone, allowing the selection of the most adequate spindle speed and depth of cut for higher productivity. However, the data used to calculate the SLD, coming from frequency response functions (FRFs), must be acquired adequately to improve the predictability. FRFs result differently depending on the activation of the spindle electronic control. The present work uses SLDs to investigate these differences and experimental end milling tests to assess the accuracy of SLDs curves. Results indicate that the inclusion of spindle electronic control provides better accuracy in predicting the chatter in milling.

References

1.
Tobias
,
S. A.
,
1965
,
Machine Tool Vibration
,
Blackie and Sons, Ltd.
,
London
.
2.
Koenigsberger
,
F.
, and
Tlusty
,
J.
,
1967
,
Machine Tool Structures—V06. I: Stability Against Chatter
,
Pergamon Press
,
New York
.
3.
Quintana
,
G.
, and
Ciurana
,
J.
,
2011
, “
Chatter in Machining Processes: A Review
,”
Int. J. Mach. Tools Manuf.
,
51
, pp.
363
376
.10.1016/j.ijmachtools.2011.01.001
4.
Tajalli
,
S. A.
,
Movahhedy
,
M. R.
, and
Akbari
,
J.
,
2013
, “
Size Dependent Vibrations of Micro-End Mill Incorporating Strain Gradient Elasticity Theory
,”
J. Sound Vib.
,
332
, pp.
3922
3944
.10.1016/j.jsv.2013.01.038
5.
Jin
,
X.
, and
Altintas
,
Y.
,
2013
, “
Chatter Stability Model of Micro-Milling With Process Damping
,”
ASME J. Manuf. Sci. Eng.
,
135
(
3
), p.
031011
.10.1115/1.4024038
6.
Budak
,
E.
, and
Altintas
,
Y.
,
1995
, “
Analytical Prediction of Stability Lobes in Milling
,”
Ann. CIRP
,
44
(
1
), pp.
357
362
.10.1016/S0007-8506(07)62342-7
7.
Sims
,
N. D.
,
2007
, “
Vibration Absorbers for Chatter Suppression: A New Analytical Tuning Methodology
,”
J. Sound Vib.
,
301
, pp.
592
607
.10.1016/j.jsv.2006.10.020
8.
Altintas
,
Y.
,
Yang
,
Y.
, and
Muñoa
,
J.
,
2010
, “
Optimization of Multiple Tuned Mass Dampers to Suppress Machine Tool Chatter
,”
Int. J. Mach. Tools Manuf.
,
50
, pp.
834
842
.10.1016/j.ijmachtools.2010.04.011
9.
Chung
,
B.
,
Smith
,
S.
, and
Tlusty
,
J.
,
1997
, “
Active Damping of Structural Modes in High Speed Machine Tools
,”
J. Vib. Control
,
3
, pp.
279
295
.10.1177/107754639700300303
10.
Suh
,
J. D.
, and
Lee
,
D. G.
,
2008
, “
Design and Manufacture of Hybrid Polymer Concrete Bed for High-Speed CNC Milling Machine
,”
Int. J. Mech. Mater. Des.
,
4
(
2
), pp.
113
121
.10.1007/s10999-007-9033-3
11.
Sims
,
N. D.
,
Mann
,
B.
, and
Huyanan
,
S.
,
2008
, “
Analytical Prediction of Chatter Stability for Variable Pitch and Variable Helix Milling Tools
,”
J. Sound Vib.
,
307
, pp.
664
686
.10.1016/j.jsv.2008.03.045
12.
Altintas
,
Y.
, et al.,
2010
, “
The Effect of Serration on Mechanics and Stability of Milling Cutters
,”
Int. J. Mach. Tools Manuf.
,
50
, pp.
511
520
.10.1016/j.ijmachtools.2010.03.006
13.
Gatti
,
P. L.
, and
Ferrari
,
V.
,
2003
,
Applied Structural and Mechanical Vibrations Theory, Methods and Measuring, Instrumentation
,
Taylor & Francis e-Library
,
London
.
14.
Ewins
,
D. J.
,
1984
,
Modal Testing: Theory and Practice
,
John Wiley & Sons
,
New York
.
15.
Altintas
,
Y.
,
Namazi
,
M.
,
Abe
,
T.
, and
Rajapakse
,
N.
,
2007
, “
Modeling and Identification of Tool Holder–Spindle Interface Dynamics
,”
Int. J. Mach. Tools Manuf.
,
47
, pp.
1333
1341
.10.1016/j.ijmachtools.2007.01.010
16.
Mohit
,
L.
,
Phani
,
A. S.
, and
Altintas
,
Y.
,
2013
, “
Position-Dependent Multibody Dynamic Modeling of Machine Tools Based on Improved Reduced Order Models
,”
ASME J. Manuf. Sci. Eng.
,
135
(
2
), p.
021008
. 10.1115/1.4023453
17.
Altintas
,
Y.
,
Maeda
,
O.
, and
Cao
,
Y.
,
2005
, “
Expert Spindle Design System
,”
Int. J. Mach. Tools Manuf.
,
45
, pp.
537
548
.10.1016/j.ijmachtools.2004.08.021
18.
Altintas
,
Y.
, and
Cao
,
Y.
,
2007
, “
Modeling of Spindle-Bearing and Machine Tool Systems for Virtual Simulation of Milling Operations
,”
Int. J. Mach. Tools Manuf.
,
47
, pp.
1342
1350
.10.1016/j.ijmachtools.2007.01.010
19.
Sims
,
N. D.
,
Bayly
,
P.
V
.
,
Young
,
K. A.
,
2005
, “
Piezoelectric Sensors and Actuators for Milling Tool Stability Lobes
,”
J. Sound Vib.
,
281
, pp.
743
762
.10.1016/j.jsv.2004.02.014
20.
McConnell
,
K. G.
,
1995
,
Vibration Testing: Theory and Practice
,
Wiley
,
New York
.
21.
Maia
,
N. M. M.
, and
Silva
,
J. M. M.
,
1997
,
Theoretical and Experimental Modal Analysis
,
Wiley
,
New York
.
22.
Landers
,
R. G.
, and
Ulsoy
,
A. G.
,
2008
, “
Nonlinear Feed Effect in Machining Chatter Analysis
,”
ASME J. Manuf. Sci. Eng.
,
130
, pp.
1
8
.10.1115/1.2783276
23.
Gagnol
, V
.
,
Bouzgarrou
,
B. C.
,
Ray
,
P.
, and
Barra
,
C.
,
2007
, “
Model-Based Chatter Stability Prediction for High-Speed Spindles
,”
Int. J. Mach. Tools Manuf.
,
47
, pp.
1176
1186
.10.1016/j.ijmachtools.2006.09.002
24.
Quintana
,
G.
,
Ciurana
,
J.
, and
Teixidor
,
D.
,
2008
, “
A New Experimental Methodology for Identification of Stability Lobes Diagram in Milling Operations
,”
Int. J. Mach. Tools Manuf.
,
48
, pp.
1637
1645
.10.1016/j.ijmachtools.2008.07.006
25.
Yoon
,
M. C.
, and
Chin
,
D. H.
,
2005
, “
Cutting Force Monitoring in the End Milling Operation for Chatter Detection
,”
J. Eng. Manuf.
,
219
, pp.
455
465
.10.1243/095440505X32292
26.
Toh
,
C. K.
,
2004
, “
Vibration Analysis in High Speed Rough and Finishing Milling Hardened Steel
,”
J. Sound Vib.
,
278
, pp.
101
115
.10.1016/j.jsv.2003.11.012
27.
Kuljanic
,
E.
,
Sortino
,
M.
, and
Totis
,
G.
,
2008
, “
Multisensor Approaches for Chatter Detection in Milling
,”
J. Sound Vib.
,
312
, pp.
672
693
.10.1016/j.jsv.2007.11.006
28.
Rantatalo
,
M.
,
Aidanpaa
,
J. O.
,
Goranssonc
,
B.
, and
Normand
,
P.
,
2007
, “
Milling Machine Spindle Analysis Using FEM and Non-Contact Spindle Excitation and Response Measurement
,”
Int. J. Mach. Tools Manuf.
,
47
, pp.
1034
1045
.10.1016/j.ijmachtools.2006.10.004
29.
SIEMENS, Commissioning Manual Sinumerik 840D sl, Order Number 6FC5397-2AP10-6BA0, p. 152.
30.
Park
,
S. S.
, and
Qin
,
Y. M.
,
2007
, “
Robust Regenerative Chatter Stability in Machine Tools
,”
Int. J. Adv. Manuf. Technol.
,
33
, pp.
389
402
.10.1007/s00170-006-0778-x
You do not currently have access to this content.