Chatter stability prediction for micro-milling processes with time-varying cutting force coefficients

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Journal of Vibration and Shock ›› 2018, Vol. 37 ›› Issue (3) : 160-166.

LIU Yu1 WANG zhenyu1 YANG Huigang2 ZHANG Yimin1

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Abstract

Chatter problems in milling severely affect productivity and quality of machining. Tool wear causes cutting force coefficient, process damping coefficient, and other parameters to change with cutting time. These variations significantly reduce the accuracy of chatter prediction using conventional methods. To solve this problem, the time-varying reliability theory was introduced, and Gamma process was used to describe the relationship between tool edge radius and cutting time. The models for a micro milling system’s cutting force coefficients, time-varying stability and time-varying reliability were established. The changes of the system’s chatter stability and chatter reliability with cutting time under the given conditions were analyzed. The system’s chatter time-varying stability and chatter time-varying reliability were investigated under given cutting depths and spindle speeds. The results of case study showed that with increase in cutting time, the system’s chatter stability drops gradually; the proposed method can be used to predict the system’s chatter stability more accurately within different cutting time intervals.

Key words

tool edge radius / cutting force coefficients / Gamma process / chatter time-varying stability / chatter time-varying reliability

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LIU Yu1 WANG zhenyu1 YANG Huigang2 ZHANG Yimin1. Chatter stability prediction for micro-milling processes with time-varying cutting force coefficients[J]. Journal of Vibration and Shock, 2018, 37(3): 160-166

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