Skip to main content
SpringerLink
Log in

Effect of the interaction between tool and workpiece modes on turning with round inserts

  • Published:
International Journal of Dynamics and Control Aims and scope Submit manuscript

Abstract

In this paper we investigate the effect of the tool-workpiece mode interaction on the stability of a flexible-tool, flexible-workpiece turning process. The workpiece dynamics are modeled by classical beam theory while for the tool we consider a description in terms of eigenmodes with an arbitrary orientation. The focus here is on elucidating the coupling effects due to the flexibility of both structures. Specifically, we show how the tool location along the workpiece and the dynamics of both the workpiece and the tool affect stability. Another contribution of this paper is the utilization of a novel analytical force model for cutting with round inserts. Using this force model, we further show that when round inserts are present, commonly used frequency domain methods can no longer be utilized to capture the system stability. Consequently, we use the spectral element approach, a highly-efficient time-domain approach, for studying the system stability.

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

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5

Similar content being viewed by others

References

  1. Tobias SA, Fishwick W (1958) Theory of regenerative machine tool chatter. Engineering 205:199–203

    Google Scholar 

  2. Quintana G, Ciurana J (2011) Chatter in machining processes: a review. Int J Mach Tools Manuf 51(5):363–376. doi:10.1016/j.ijmachtools.2011.01.001

    Article  Google Scholar 

  3. Arnaud L, Gonzalo O, Seguy S, Jauregi H, Peigne G (2011) Simulation of low rigidity part machining applied to thin-walled structures. Int J Adv Manuf Technol 54(5–8):479–488. doi:10.1007/s00170-010-2976-9

    Article  Google Scholar 

  4. Gang L (2009) Study on deformation of titanium thin-walled part in milling process. J Mater Proc Technol 209(6):2788–2793

    Article  Google Scholar 

  5. Mehdi K, Rigal J, Play D (2002) Dynamic behavior of a thin-walled cylindrical workpiece during the turning process, part 1: cutting process simulation. J Manuf Sci Eng 124(3):562–568. doi:10.1115/1.1431260

    Article  Google Scholar 

  6. Yu SD, Shah V (2009) Theoretical and experimental studies of chatter in turning for uniform and stepped workpieces. J Vib Acoust 130(6):061,005

    Article  Google Scholar 

  7. Sutherland JW, DeVor RE (1986) An improved method for cutting force and surface error prediction in flexible end milling systems. J Manuf Sci Eng 108(4):269–279. doi:10.1115/1.3187077

    Google Scholar 

  8. Davies M, Balachandran B (2000) Impact dynamics in milling of thin-walled structures. Nonlinear Dyn 22(4):375–392. doi:10.1023/A:1008364405411

    Article  MATH  Google Scholar 

  9. Ratchev S, Liu S, Huang W, Becker A (2004) A flexible force model for end milling of low-rigidity parts. J Mater Process Technol 153:134–138. doi:10.1016/j.jmatprotec.2004.04.300

    Article  Google Scholar 

  10. Altintaş Y, Budak E (1995) Analytical prediction of stability lobes in milling. CIRP Ann 44(1):357–362

    Article  Google Scholar 

  11. Lan JVL, Marty A, Debongnie JF (2007) Providing stability maps for milling operations. Int J Mach Tools Manuf 47(9):1493–1496

    Article  Google Scholar 

  12. Budak E (2006) Analytical models for high performance milling. Part i: cutting forces, structural deformations and tolerance integrity. Int J Mach Tools Manuf 46(12–13):1478–1488. doi:10.1016/j.ijmachtools.2005.09.009

    Article  Google Scholar 

  13. Tongyue W, Ning H, Liang L (2010) Stability of milling of thin-walled workpiece. In: 2010 international conference on mechanic automation and control engineering (MACE), pp 3408–3411. doi:10.1109/MACE.2010.5536868

  14. Wanner B, Eynian M, Beno T, Pejryd L (2012) Process stability strategies in milling of thin-walled inconel 718. In: AIP conference proceedings, vol 1431, no 1, pp 465–472. doi:10.1063/1.4707597

  15. Thevenot V, Arnaud L, Dessein G, Cazenave-Larroche G (2006) Influence of material removal on the dynamic behavior of thin-walled structures in peripheral milling. Mach Sci Technol 10(3):275–287

    Article  Google Scholar 

  16. Bravo U, Altuzarra O, de Lacalle LL, Sanchez J, Campa F (2005) Stability limits of milling considering the flexibility of the workpiece and the machine. Int J Mach Tools Manuf 45(15):1669–1680

    Article  Google Scholar 

  17. Chen C, Tsao Y (2006) A stability analysis of turning a tailstock supported flexible work-piece. Int J Mach Tools Manuf 46(1):18–25. doi:10.1016/j.ijmachtools.2005.04.002

    Article  Google Scholar 

  18. Chen CK, Tsao YM (2006) A stability analysis of regenerative chatter in turning process without using tailstock. Int J Adv Manuf Technol 29(7–8):648–654

    Article  Google Scholar 

  19. Vela-Martinez L, Jauregui-Correa J, Rubio-Cerda E, Herrera-Ruiz G, Lozano-Guzmï£.n A (2008) Analysis of compliance between the cutting tool and the workpiece on the stability of a turning process. Int J Mach Tools Manuf 48(9):1054–1062 Cited By (since 1996)19

    Article  Google Scholar 

  20. Khasawneh FA, Bobrenkov OA, Mann BP, Butcher EA (2012) Investigation of period-doubling islands in milling with simultaneously engaged helical flutes. J Vib Acoust 134(2):021,008. doi:10.1115/1.4005022

    Article  Google Scholar 

  21. Patel BR, Mann BP, Young KA (2008) Uncharted islands of chatter instability in milling. Int J Mach Tools Manuf 48:124–134

    Article  Google Scholar 

  22. Szalai R, Stépán G (2006) Lobes and lenses in the stability chart of interrupted turning. J Comput Nonlinear Dyn 1:205–211

    Article  Google Scholar 

  23. Altintas Y, Stepan G, Merdol D, Dombovari Z (2008) Chatter stability of milling in frequency and discrete time domain. CIRP J Manuf Sci Technol 1(1):35–44. doi:10.1016/j.cirpj.2008.06.003

    Article  Google Scholar 

  24. Insperger T, Barton DA, Stepan G (2008) Criticality of hopf bifurcation in state-dependent delay model of turning processes. Int J Nonlinear Mech 43(2):140–149. doi:10.1016/j.ijnonlinmec.2007.11.002

    Article  MATH  Google Scholar 

  25. Insperger T, Stepan G (2004) Stability analysis of turning with periodic spindle speed modulation via semidiscretization. J Vib Control 12:1835–1855. doi:10.1177/1077546304044891

    MATH  Google Scholar 

  26. Bobrenkov O, Khasawneh F, Butcher E, Mann B (2010) Analysis of milling dynamics for simultaneously engaged cutting teeth. J Sound Vib 329(5):585–606. doi:10.1016/j.jsv.2009.09.032

    Article  Google Scholar 

  27. Butcher E, Bobrenkov O, Bueler E, Nindujarla P (2009) Analysis of milling stability by the Chebyshev collocation method: algorithm and optimal stable immersion levels. J Comput Nonlinear Dyn 4(3):031,003

    Article  Google Scholar 

  28. Totis G, Albertelli P, Sortino M, Monno M (2014) Efficient evaluation of process stability in milling with spindle speed variation by using the Chebyshev collocation method. J Sound Vib 333(3):646–668. doi:10.1016/j.jsv.2013.09.043

    Article  Google Scholar 

  29. Insperger T, Mann BP, Stépán G, Bayly PV (2003) Stability of up-milling and down-milling. Part 1: alternative analytical methods. Int J Mach Tools Manuf 43:25–34

    Article  Google Scholar 

  30. Khasawneh FA, Mann B, Insperger T, Stépán G (2009) Increased stability of low-speed turning through a distributed force and continuous delay model. J Comput Nonlinear Dyn 4(4):041,003

    Article  Google Scholar 

  31. Mann BP, Bayly PV, Davies MA, Halley JE (2004) Limit cycles, bifurcations, and accuracy of the milling process. J Sound Vib 277:31–48

    Article  Google Scholar 

  32. Song Q, Ai X, Tang W (2011) Prediction of simultaneous dynamic stability limit of time-variable parameters system in thin-walled workpiece high-speed milling processes. Int J Adv Manuf Technol 55(9–12):883–889

    Article  Google Scholar 

  33. Insperger T, Stépán G (2002) Semi-discretization method for delayed systems. Int J Numer Methods Eng 55:503–518

    Article  MathSciNet  MATH  Google Scholar 

  34. Insperger T, Stépán G (2004) Updated semi-discretization method for periodic delay-differential equations with discrete delay. Int J Numer Methods 61:117–141

    Article  MathSciNet  MATH  Google Scholar 

  35. Insperger T, Stepan G, Turi J (2008) On the higher-order semi-discretizations for periodic delayed systems. J Sound Vib 313:334–341

    Article  Google Scholar 

  36. Eksioglu C, Kilic Z, Altintas Y (2012) Discrete-time prediction of chatter stability, cutting forces, and surface location errors in flexible milling systems. J Manuf Sci Eng 134(6):061,006

    Article  Google Scholar 

  37. Khasawneh FA, Mann BP (2011) A spectral element approach for the stability of delay systems. Int J Numer Methods Eng 87(6):566–592. doi:10.1002/nme.3122

    Article  MathSciNet  MATH  Google Scholar 

  38. Yavari A, Sarkani S, Jr EM (2000) On applications of generalized functions to beam bending problems. Int J Solids Struct 37(40):5675–5705. doi:10.1016/S0020-7683(99)00271-1

    Article  MathSciNet  MATH  Google Scholar 

  39. Li H, Song G, Hou J, Li S, Wen B (2013) A stability analysis of turning process considering the workpiece as a timoshenko beam. J Vibroeng 15(4):1927–1939 Cited By (since 1996)0

    Google Scholar 

  40. Altintaş Y (2000) Manufacturing automation, 1st edn. Cambridge University Press, New York. doi:10.2277/0521659736

    Google Scholar 

  41. Otto A, Khasawneh F, Radons G (2015) Position-dependent stability analysis of turning with tool and workpiece compliance. Int J Adv Manuf Technol 79(9–12):1453–1463. doi:10.1007/s00170-015-6929-1

    Article  Google Scholar 

  42. Otto A, Rauh S, Kolouch M, Radons G (2014) Extension of tlusty’s law for the identification of chatter stability lobes in multi-dimensional cutting processes. Int J Mach Tools Manuf 82:50–58

    Article  Google Scholar 

  43. Law M, Altintas Y, Phani AS (2013) Rapid evaluation and optimization of machine tools with position-dependent stability. Int J Mach Tools Manuf 68:81–90. doi:10.1016/j.ijmachtools.2013.02.003

    Article  Google Scholar 

  44. Law,M, Phani AS, Altintas Y (2013) Position-dependent multibody dynamic modeling of machine tools based on improved reduced order models. J Manuf Sci Eng 135(2):021,008. doi:10.1115/1.4023453

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Michigan State University, East Lansing, MI, 48824, USA

    Firas A. Khasawneh

  2. Institute for Physics, TU Chemnitz, 09107, Chemnitz, Germany

    Andreas Otto

Authors
  1. Firas A. Khasawneh
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Andreas Otto
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Firas A. Khasawneh.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Khasawneh, F.A., Otto, A. Effect of the interaction between tool and workpiece modes on turning with round inserts. Int. J. Dynam. Control 6, 571–581 (2018). https://doi.org/10.1007/s40435-017-0344-4

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s40435-017-0344-4

Keywords

Search

Navigation