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Extension of process damping to milling with low radial immersion

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Abstract

This paper investigates the stabilizing effect of process damping at low cutting speeds for regenerative machine tool vibrations of milling processes. The process damping is induced by a velocity-dependent cutting force model, which takes into account that the actual cutting velocity is different from the nominal one during machine tool vibrations. The chip thickness and the cutting force are calculated according to the direction of the actual cutting velocity. This results in an additional damping term in the governing delay-differential equation, which is time-periodic for milling and inversely proportional to the cutting speed. In the literature, this term is often assumed to be constant and is considered to improve stability properties at low spindle speeds. In this paper, it is shown that the velocity-dependent cutting force model captures the improvement in the low-speed stability only for turning operations and milling with large radial immersion, while it results in a negative process damping term for low-immersion milling. Consequently, an extended process damping model is needed to explain the low-speed stability improvement for low radial immersion milling.

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Authors and Affiliations

  1. Department of Applied Mechanics, Budapest University of Technology and Economics, H-1111, Budapest, Hungary

    Tamás G. Molnár, Dániel Bachrathy & Gábor Stépán

  2. Department of Applied Mechanics, Budapest University of Technology and Economics and MTA-BME Lendület Human Balancing Research Group, H-1111, Budapest, Hungary

    Tamás Insperger

Authors
  1. Tamás G. Molnár
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  2. Tamás Insperger
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  3. Dániel Bachrathy
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  4. Gábor Stépán
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Corresponding author

Correspondence to Tamás G. Molnár.

Additional information

This work has been supported by the Ú NKP-16-3-I. New National Excellence Program of the Ministry of Human Capacities. This work was supported by the Hungarian National Science Foundation under grant OTKA-K105433. The research leading to these results has received funding from the European Research Council under the European Union’s Seventh Framework Programme (FP/2007-2013) / ERC Advanced Grant Agreement n. 340889.

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Molnár, T.G., Insperger, T., Bachrathy, D. et al. Extension of process damping to milling with low radial immersion. Int J Adv Manuf Technol 89, 2545–2556 (2017). https://doi.org/10.1007/s00170-016-9780-0

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  • DOI: https://doi.org/10.1007/s00170-016-9780-0

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