HighSpeedMillingChatterwithVariablePitchCutter.pptVIP

ACC 2006 The Problem and Motivation Process Dynamics Review of CTCR Paradigm (A unique process for Multiple Time Delayed Systems) Measure of Chatter Rejection Optimization problem Variable vs. Uniform Pitch Cutter Process Dynamics System Characteristic Equation four-flute-two-pitch cutter : CTCR reveals the stability regions * Comparison of CTCR results Measure of chatter rejection: Finding the real part of rightmost characteristic roots (still an open problem in mathematics) Status-quo: Numerical approximations: Infinitesimal Generator Approx. [D. Breda 2005] DDE-BIFTOOL [K. Engelborghs 2000] ….. Optimization Problem Objective: Maximizing the metal removal rate while avoiding the onset of chatter The pitch angle selection on the tool. Optimum depth of cut and the spindle speed? Objective function: Measure of chatter rejection: Preliminary results: OPTIMUM CONDITIONS FOR VARIABLE PITCH MILLING Hassan Fazelinia ? Nejat Olgac Department of Mechanical Engineering University of Connecticut Outline Uniform Pitch end mill ?1= 90? ?2= 90? Variable Pitch end mill ?1= 70? ?2= 110? Notable earlier work: [1] Slavicek, J., 1965, “The Effect of Irregular Tooth Pitch on Stability of Milling.” 6th MTDR Conference, London, Pergamon Press. [2] Minis, I. and Yanushevsky, R. , 1993, A New Theoretical Approach for the Prediction of Machine Tool Chatter in Milling. ASME Journal of Engineering for Industry 115(1), 1-8. [3] Altintas, Y. and Budak, E., 1995, Analytical Prediction of Stability Lobes in Milling. Annals of the CIRP 44(1), 357-362. + Feed Olgac, N. and Sipahi, R., “A Unique Methodology for Chatter Stability Mapping in Simultaneous Machining”. ASME, Journal of Manufacturing Science and Engineering, 2005. 127(4). Sipahi, R. and Olgac, N. , Stability in Variable-Pitch Milling Regarding Regenerative Chatter, IMECE 2006 Cutter force formation chip loads (process / material specific) Cutter dynamics ID (setup specific) Stability outlook for 4 mm axial