Abstract
Chatter is a very common phenomenon and severely affects the productivity and quality of workpiece during milling. However, it is very difficult and expensive to suppress chatter directly in machining. The main method involves avoiding chatter by predicting chatter stability. Tool wear is a difficult and unavoidable problem in micromilling and significantly affects the prediction of chatter stability, but it was neglected in the currently available chatter stability prediction methods. To establish the relationship between tool wear and chatter stability, models were established for the process damping coefficients and gamma process of tool wear with cutting edge radius. Based on these models, equations were derived for the time-varying chatter stability and reliability of micromilling systems. In the proposed method, the stability lobe diagram (SLD) increases with the cutting time, maintaining the accuracy of chatter stability prediction at different cutting times. The method also can concisely express the position relationship between the axial depth of cut and critical depth with the number of chatter reliability, more accurate than the traditional methods. The corresponding experimental verification was carried out. The results show that the process damping force and critical depth of micromilling systems gradually increase with the cutting time, and the proposed method is consistent with the results.
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This work was supported by the National Natural Science Foundation of China (51575094, 51875094) and the fundamental research funds for the central universities of china (NI70304020).
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Wang, Z., Yang, Y., Liu, Y. et al. Prediction of time-varying chatter stability: effect of tool wear. Int J Adv Manuf Technol 99, 2705–2716 (2018). https://doi.org/10.1007/s00170-018-2582-9
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DOI: https://doi.org/10.1007/s00170-018-2582-9