Possibilities of using stability lobe diagram for stability prediction of high speed milling of thin-walled details

Authors

  • Yu. Vnukov Zaporizhzhya National Technical University, Zaporizhzhya, Ukraine
  • A. Germashev Zaporizhzhya National Technical University, Zaporizhzhya, Ukraine
  • V. Logominov Zaporizhzhya National Technical University, Zaporizhzhya, Ukraine
  • V. Kryshtal Ivchenko-Progress, Zaporizhzhya, Ukraine

DOI:

https://doi.org/10.20535/2521-1943.2017.79.96079

Keywords:

Thin-walled detail, high-speed milling, chatter, stability, surface finish

Abstract

High-speed milling is a cost and time effective process, which becomes more popular nowadays. It especially available at milling of thin-walled structures of airfoil components. Manufacturer often faced with problem of producing thin-walled parts due to vibration and stability lobes theory in a lot of cases does not allow to avoid this problem by choosing the appropriate cutting conditions. In practice cutting condition for milling of thin walled detail is usually obtained by experimental way. In this paper authors present main differences of thin-walled end milling from classical end milling and show features of thin-walled end milling process and aspects, which effect on quality of surface finish. The aim of the paper is to validate that at high speed thin-walled end milling not only chatter is the reason of unstable cutting condition. Evaluation of stability, obtained by experimental tests, was compared with stability lobe diagram.

Author Biographies

Yu. Vnukov, Zaporizhzhya National Technical University, Zaporizhzhya

ProfessorDr. Sc.

A. Germashev, Zaporizhzhya National Technical University, Zaporizhzhya

Ph.D

V. Logominov, Zaporizhzhya National Technical University, Zaporizhzhya

Ph.D

References

  1. Tobias, S. A. (1965), Machine Tool Vibration, Wiley, N.Y.
  2. Koenigsberger, I., Tlusty, J. (1971), Structures of Machine Tools, Pergamon Press.
  3. Merritt, H. E. (1965), Theory of Self-Excited Machine Tool Chatter, ASME Journal of Engineering for Industry, Vol. 87, pp. 447-454.
  4. Week, M. (1985), Handbook of Machine Tools, Vol. 4, Wiley, N. Y.
  5. Minis, I., Magrab, E., and Pandelidis, I. (1990), Improved Methods for the Prediction of Chatter in Turning. Part III: A Generalized Linear Theory, ASME Journal of Engineering for Industry, Vol. 112, pp. 28-35.
  6. Tlusty, J. (1986), ‘Dynamics of high-speed milling’, Journal of Engineering for Industry 108, 59–67.
  7. Tlusty, J., Ismail, F. (1983), ‘Special aspects of chatter in milling’, Journal of Vibration, Acoustics, Stress, and Reliability in Design 105, P. pp. 24-32.
  8. Shridar, R., Hohn, R. E., Long, G. W. (1968) A general formulation of the milling process equation, Journal of Engineering for Industry 90, pp. 317-324.
  9. Shridar, R., Hohn, R. E., Long, G. W. (1968), A stability algorithm for the general milling process, Journal of Engineering for Industry 90, pp. 330-334 .
  10. Shridar, R., Hohn, R. E., Long, G. W. (1968), A stability algorithm for a special case of the milling process, Journal of Engineering for Industry 90, pp. 325-329.
  11. Minis, I. and Yanushevsky, R. (1993), A new theoretical approach for prediction of chatter in milling, Journal of Engineering for Industry 115, pp. 1–8.
  12. Altintas, Y. and Lee, P. (1996), A general mechanics and dynamics model for helical end mills, Annals of the CIRP 45(1), pp. 59–64.
  13. Smith, S. and Tlusty, J. (1991), An overview of modelling and simulation of the milling process, ASME Journal of Engineering for Industry 113, pp. 169–175.
  14. Rusinek, R. and Zaleski, K. (2016), ‘Dynamics of thin-walled element milling expressed by recurrence analysis’, Meccanica. An International Journal of Theoretical and Applied Mechanics, Vol. 51, Issue 6, pp. 1275–1286.
  15. Vnukov Y.N., Djadja S.I., Kozlova E.B., Chernovol N.N. (2014), Analyses of contact features of cutting tool and detail in cylindrical end milling, Journal of Engineering Science, Vol 4. - pp. 1-7.
  16. Davies, M. A., Pratt, J. R., Dutterer, B., and Burns, T. J. (2000), The stability of low radial immersion milling, CIRP Annals-Manufacturing Technology 49 (1), pp. 37-40.
  17. Insperger, T. and Stépán, G. (2011), Semi-discretization for time-delay systems: stability and engineering applications (Vol. 178). Springer Science & Business Media, 174 p.
  18. Insperger, T., and Stépán, G. (2004), Vibration Frequencies in High-Speed Milling Processes or a Positive Answer to Davies, Pratt, Dutterer and Burns T. Insperger, J. Manuf. Sci. Eng 126 (3), pp. 481-487.
  19. Logominov, V., Germashev, A., Diadia, S., and Kozlova, O. (2014) Testbench for study of oscillations at final milling of part cylindrical thin-walled elements, 12 p.
  20. Vnukov, Y., Hermashev, A., Kuchuhurov, M., Diadia, S., Kozlova, O. (2015), Stand for investigation of workpiece oscillating process under cylindrical cutting, 11 p.
  21. Vnukov, Y., Lovominov, V., and Kamorkin, P. (2014), Stand for research mechanical oscillations in end milling of flexible workpieces by end mill, Cutting and tool in technological system: International ScientificTechnical Collection, 80, pp. 32–37.
  22. Vnukov Y.N., Germashev A.I., Djadja S.I., Kozlova E.B. (2015), Methodology of contact condition determination of the tool and thin-walled detail during end milling, Cutting & tool in technological system: International ScientificTechnical Collection, NTU “KhPI”, Edition 85, pp. 48-55.

Downloads

Published

2017-06-22

How to Cite

[1]
Y. Vnukov, A. Germashev, V. Logominov, and V. Kryshtal, “Possibilities of using stability lobe diagram for stability prediction of high speed milling of thin-walled details”, Mech. Adv. Technol., no. 1(79), pp. 41–48, Jun. 2017.

Issue

No. 1(79) (2017)

Section

Original study

License

Copyright (c) 2020 Mechanics and Advanced Technologies

Creative Commons License

This work is licensed under a Creative Commons Attribution 4.0 International License.

The ownership of copyright remains with the Authors.
 
Authors may use their own material in other publications provided that the Journal is acknowledged as the original place of publication and National Technical University of Ukraine “Igor Sikorsky Kyiv Polytechnic Institute” as the Publisher.

Authors who publish with this journal agree to the following terms:

  1. Authors retain copyright and grant the journal right of first publication with the work simultaneously licensed under CC BY 4.0 that allows others to share the work with an acknowledgement of the work's authorship and initial publication in this journal.

  2. Authors are able to enter into separate, additional contractual arrangements for the non-exclusive distribution of the journal's published version of the work (e.g., post it to an institutional repository or publish it in a book), with an acknowledgement of its initial publication in this journal.

  3. Authors are permitted and encouraged to post their work online (e.g., in institutional repositories or on their website) prior to and during the submission process, as it can lead to productive exchanges, as well as earlier and greater citation of published work