Dynamic Analysis and Control

  • Erhan Budak
Part of the Springer Series in Advanced Manufacturing book series (SSAM)

Abstract

All machining processes are subject to dynamic effects due to transient or forced vibrations, and dynamic mechanisms inherent to the process such as regeneration. If not controlled, they may result in high amplitude oscillations, instability and poor quality. Dynamic rigidity of the structures involved in the machining is very important in determining the dynamic behaviour of the process. Structural rigidity is also critical for deformations, and the dimensional quality of machined parts. In this chapter, important aspects of the machining process dynamics are discussed, and the methods that can be used for the analysis and modelling of the machine tool structural components and the processes are presented. Chatter stability and suppression methods will also be explained with applications.

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. [1]
    Merchant, M. E., Basic mechanics of the metal cutting process, ASME Journal of Applied Mechanics, 66, 1944, 168–175.Google Scholar
  2. [2]
    Armarego, E.J.A., Brown, R.H., The Machining of Metals, Prentice–Hall, London, 1969.Google Scholar
  3. [3]
    Armarego, E.J.A., Whitfield, R.C., Computer based modelling of popular machining operations for force and power predictions, Annals of the CIRP 34, 1985, 65–69.CrossRefGoogle Scholar
  4. [4]
    Budak, E. and Altintas, Y., Prediction of milling force coefficients from orthogonal cutting data, ASME 1993 Winter Annual Meeting, New Orleans, USA, Manufacturing Science and Engineering, 1993, 453–459.Google Scholar
  5. [5]
    Stabler, G.V., Fundamental geometry of cutting tools, Proceedings of the Institution of Mechanical Engineers, 1951, 14–26.Google Scholar
  6. [6]
    Budak, E., Altintas, Y., Armarego, E.J.A., Prediction of milling force coefficients from orthogonal cutting data, Trans. ASME Journal of Manufacturing Science and Engineering, 118, 1996, 216–224.CrossRefGoogle Scholar
  7. [7]
    Altintas, Y., Manufacturing Automation, Cambridge University Press, 2000.Google Scholar
  8. [8]
    Budak, E., The mechanics and dynamics of milling thin–walled structures, Ph.D. Dissertation, University of British Columbia, 1994.Google Scholar
  9. [9]
    Budak, E., Altintas, Y., Peripheral milling conditions for improved dimensional accuracy. International Journal of Machine Tool Design and Research, 34/7, 1994, 907–918.Google Scholar
  10. [10]
    Kops, L., Vo, D.T., Determination of the equivalent diameter of an end mill based on its compliance, Annals of the CIRP 39, 1990, 93–96.CrossRefGoogle Scholar
  11. [11]
    Kivanc, E., Budak, E., Structural modelling of end mills for form error and stability analysis, International Journal of Machine Tools and Manufacture, 44/11, 2004, 1151–1161.CrossRefGoogle Scholar
  12. [12]
    Nemes, J.A., Asamoah–Attiah, S. and Budak, E., Cutting Load Capacity of End Mills with Complex Geometry, Annals of the CIRP, 50/1, 2001, 65–68.CrossRefGoogle Scholar
  13. [13]
    Rivin, E., Stiffness and Damping in Mechanical Design, Marcel Dekker, NY, 1999.Google Scholar
  14. [14]
    Budak, E., Altintas, Y., Modelling and avoidance of static deformations in peripheral milling of plates, International Journal of Machine Tool Design and Research 35/3, 1995, 459–476.Google Scholar
  15. [15]
    Budak, E., Altintas, Y., Flexible milling force model for improved surface error predictions, ASME 1992 European Joint Conference on Engineering Systems Design and Analysis, Istanbul, Turkey, ASME PD–Vol. 47–1, 1992.Google Scholar
  16. [16]
    Ewins, D.J., Modal Testing: Theory, Practice and Application, Taylor & Francis Group; 2nd edition, London, 2001.Google Scholar
  17. [17]
    T. Schmitz, R. Donaldson, Predicting high–speed machining dynamics by substructure analysis, Annals of the CIRP 49/1, 2000, 303–308.CrossRefGoogle Scholar
  18. [18]
    T. Schmitz, M. Davies, M. Kennedy, Tool point frequency response prediction for high–speed machining by RCSA, Journal of Manufacturing Science and Engineering 123, 2001, 700–707.CrossRefGoogle Scholar
  19. [19]
    Ertürk, A., Özgüven, H.N. and Budak, E., Analytical modelling of spindle–tool dynamics on machine tools using Timoshenko beam model and receptance coupling for the prediction of tool point FRF, International Journal of Machine Tools and Manufacture, 2008 (in press).Google Scholar
  20. [20]
    Ertürk, A., Özgüven, H.N. and Budak, E., Effect analysis of bearing and interface dynamics on tool point FRF for chatter stability in machine tools by using a new analytical model for spindle–tool assemblies, International Journal of Machine Tools and Manufacture, 2008 (in press).Google Scholar
  21. [21]
    Özgüven, H.N., A new method for harmonic response of non–proportionally damped structures using undamped modal data, Journal of Sound and Vibration, 117, 1987, 313–328.CrossRefGoogle Scholar
  22. [22]
    Tlusty, J., Analysis of the state of research in cutting dynamics, Annals of the CIRP 27/2, 1978, 583–589.Google Scholar
  23. [23]
    Altintas, Y. and Weck, M. Chatter stability of metal cutting and grinding, Annals of the CIRP, 53/2, 2004, 619–642.CrossRefGoogle Scholar
  24. [24]
    Nigm, M.M. and Sadek, M.M., Experimental investigation of the characteristics of dynamic cutting process, Trans. ASME Journal of Engineering for Industry, 1977, 410–418.Google Scholar
  25. [25]
    Wu, D.W. and Liu, C.R., An analytical model of cutting dynamics, Part I: model building, Trans. ASME Journal of Engineering for Industry, 107, 1985, 107–111.CrossRefGoogle Scholar
  26. [26]
    Tlusty, J. and Rao, S.B., Verification and analysis of some dynamic cutting force coefficients data, Proceedings of the 6th NAMRC, University of Florida, USA, 1978, 420–426.Google Scholar
  27. [27]
    Tlusty, J., Polacek, M., The stability of machine tools against self excited vibrations in machining, International Research in Production Engineering, ASME, 1963, 465–474.Google Scholar
  28. [28]
    Tobias, S.A. and Fishwick, W., The chatter of lathe tools under orthogonal cutting conditions, Transactions of ASME, 80, 1958, 1079–1088.Google Scholar
  29. [29]
    Özlü, E. and Budak, E., Analytical prediction of stability limit in turning operations, Proceedings of the 9th Workshop on the Modelling of Machining Operations, Bled, Slovenia, May 2006.Google Scholar
  30. [30]
    Budak, E. and Altintas, Y., Analytical prediction of chatter stability in milling–part I: general, Trans. ASME Journal of Dynamic Systems, Measurement and Control, 120, 1998, 22–30.CrossRefGoogle Scholar
  31. [31]
    Merdol, S.D. and Altintas, Y., Multi frequency solution of chatter stability limits for low immersion milling, Trans. ASME Journal of Manufacturing Science and Engineering, 126, 2004, 459–466.CrossRefGoogle Scholar
  32. [32]
    Weck, M., Altintas, Y. and Beer, C., CAD assisted chatter free NC tool path generation in milling, International Journal of Machine Tools and Manufacture, 34, 1994, 879–891.CrossRefGoogle Scholar
  33. [33]
    Tekeli, A. and Budak, E., Maximization of chatter free material removal rate in end milling using analytical methods, Journal of Machining Science and Technology 9, 2005, 147–167.CrossRefGoogle Scholar
  34. [34]
    Slavicek, J. The effect of irregular tooth pitch on stability of milling, Proceedings of the 6th MTDR Conference, Manchester, UK, 1965, 15–22.Google Scholar
  35. [35]
    Vanherck, P. Increasing milling machine productivity by use of cutters with non–constant cutting edge pitch, 8th MTDR Conference 1966, 947–960.Google Scholar
  36. [36]
    Budak, E., An analytical design method for milling cutters with non constant pitch to increase stability – Part I: Theory; Part II: Application, Trans. ASME Journal of Manufacturing Science and Engineering, 125, 2003, 29–38.CrossRefGoogle Scholar

Copyright information

© Springer London 2009

Authors and Affiliations

  • Erhan Budak
    • 1
  1. 1.Faculty of Engineering and Natural SciencesSabanci UniversityIstanbulTurkey

Personalised recommendations