Skip to main content
SpringerLink
Log in

Stability analysis for variable spindle speed milling with helix angle using an improved semi-discretization method

  • Published:
Science China Technological Sciences Aims and scope Submit manuscript

Abstract

Chatter in milling is still a main obstacle in surface finish, machining accuracy and tool life. Its prediction and avoidance are challenging subjects in the machining field. In this paper, an improved semi-discretization method is proposed to predict variable spindle speed milling with helix angle. Based on tool geometry and machining theory, the cutting region is divided into five different cases to calculate the cutting force. The influences of radial immersion rate and modulation parameters relative to variable spindle speed milling are explored. By comparison with constant spindle speed, the simulation results show that the variable spindle speed scheme can obtain a larger range of stability. In short, the helix angle and variable spindle speed play an important role in the stability of milling process.

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

Similar content being viewed by others

References

  1. Altintas Y, Budak E. Analytical prediction of stability lobes in milling. CIRP Ann-Manuf Technol, 1995, 44: 357–362

    Article  Google Scholar 

  2. Davies M A, Pratt J R, Dutterer B, et al. Stability prediction for low radial immersion milling. J Manuf Sci Eng-Trans ASME, 2002, 124: 217–225

    Article  Google Scholar 

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

    Article  Google Scholar 

  4. Insperger T, Stepan G. Semi-discretization method for delayed systems. Int J Numer Methods Eng, 2002, 55: 503–518

    Article  MathSciNet  MATH  Google Scholar 

  5. Insperger T, Stepan G. Updated semi-discretization method for periodic delay-differential equations with discrete delay. Int J Numer Methods Eng, 2004, 61: 117–141

    Article  MathSciNet  MATH  Google Scholar 

  6. Insperger T, Stepan G. Semi-Discretization for Time-Delay Systems: Stability and Engineering Applications. New York: Springer-verlag, 2011

    Book  MATH  Google Scholar 

  7. Bayly P V, Halley J E, Mann B P, et al. Stability of interrupted cutting by temporal finite element analysis. J Manuf Sci Eng-Trans ASME, 2003, 125: 220–225

    Article  Google Scholar 

  8. Altintas Y, Engin S, Budak E. Analytical stability prediction and design of variable pitch cutters. J Manuf Sci Eng-Trans ASME, 1999, 121: 173–178

    Article  Google Scholar 

  9. Zatarain M, Munoa J, Peigne G, et al. Analysis of the influence of mill helix angle on chatter stability. CIRP Ann-Manuf Technol, 2006, 55: 365–368

    Article  Google Scholar 

  10. Insperger T, Munoa J, Zatarain M, et al. Unstable islands in the stability chart of milling processes due to the helix angle. In: CIRP-2nd International Conference on High Performance Cutting (HPC), Vancouver, Canada, 2006

  11. Patel B R, Mann B P, Young K A. Uncharted islands of chatter instability in milling. Int J Mach Tools Manuf, 2008, 48(1): 124–134

    Article  Google Scholar 

  12. Sims N, Mann B, Huyanan S. Analytical prediction of chatter stability for variable pitch and variable helix milling tools. J Sound Vib, 2008, 317: 664–686

    Article  Google Scholar 

  13. Wan M, Zhang W H, Dang J W, et al. A unified stability prediction method for milling process with multiple delays. Int J Mach Tools Manuf, 2010, 50: 29–41

    Article  Google Scholar 

  14. Ding Y, Zhu L M, Zhang X J, et al. Milling stability analysis using the spectral method. Sci China Tech Sci, 2011, 54: 3130–3136

    Article  MATH  Google Scholar 

  15. Takemura T, Kitamura T, Hoshi T, et al. Active suppression of chatter by programmed variation of spindle speed. CIRP Ann-Manuf Technol, 1974, 23: 121–122

    Google Scholar 

  16. Pakdemirli M, Ulsoy A. Perturbation analysis of spindle speed variation in machine tool chatter. J Vib Control, 1997, 3: 261–278

    Article  Google Scholar 

  17. Insperger T, Stepan G. Stability analysis of turning with periodic spindle speed modulation via semidiscretization. J Vib Control, 2004, 10: 1835–1855

    Article  MATH  Google Scholar 

  18. Long X H, Balachandran B. Stability of up-milling and down-milling operations with variable spindle speed. J Vib Control, 2010, 16: 1151–1168

    Article  MathSciNet  Google Scholar 

  19. Yilmaz A, Al-Regib E, Ni J. Machine tool chatter suppression by multi-level random spindle speed variation. J Manuf Sci Eng-Trans ASME, 2002, 124: 208–216

    Article  Google Scholar 

  20. Sastry S, Kapoor S G, DeVor R E, et al. Chatter stability analysis of the variable speed face-milling process. J Manuf Sci Eng-Trans ASME, 2001, 123: 753–756

    Article  Google Scholar 

  21. Seguy S, Insperger T, Arnaud L, et al. On the stability of high-speed milling with spindle speed variation. Int J Adv Manuf Technol, 2010, 48: 883–895

    Article  Google Scholar 

  22. Zatarain M, Bediaga I, Munoa J, et al. Stability of milling processes with continuous spindle speed variation: Analysis in the frequency and time domains, and experimental correlation. CIRP Ann-Manuf Technol, 2008, 57: 379–384

    Article  Google Scholar 

  23. Altintas Y. Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design. England: Cambridge University Press, 2000

    Google Scholar 

  24. Ding Y, Zhu L M, Zhang X J, et al. A full-discretization method for prediction of milling stability. Int J Mach Tools Manuf, 2010, 50, 502–509

    Article  Google Scholar 

  25. Insperger T. Full-discretization and semi-discretization for milling stability prediction: Some comments. Int J Mach Tools Manuf, 2010, 50: 658–662

    Article  Google Scholar 

  26. Xie Q Z. Matlab code: Matlab code for the improved SDM method [OL]. http://www.fileupyours.com/view/320896/program.rar, 2012-10-30

Download references

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, Tianjin University, Tianjin, 300072, China

    QiZhi Xie, QiChang Zhang, Wei Wang, Gang Jin & JianXin Han

  2. Tianjin Key Laboratory of Nonlinear Dynamics and Chaos Control, Tianjin, 300072, China

    QiZhi Xie, QiChang Zhang, Wei Wang, Gang Jin & JianXin Han

  3. State Key Laboratory of Engines, Tianjin University, Tianjin, 300072, China

    QiChang Zhang & Wei Wang

Authors
  1. QiZhi Xie
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. QiChang Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Wei Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Gang Jin
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. JianXin Han
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to QiChang Zhang.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Xie, Q., Zhang, Q., Wang, W. et al. Stability analysis for variable spindle speed milling with helix angle using an improved semi-discretization method. Sci. China Technol. Sci. 56, 648–655 (2013). https://doi.org/10.1007/s11431-012-5090-4

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11431-012-5090-4

Keywords

Search

Navigation