Stability of milling with non-uniform pitch and variable helix Tools

Research output: Contribution to journalResearch articleContributedpeer-review

Contributors

  • Andreas Otto - , Chemnitz University of Technology (Author)
  • Stefan Rauh - , Fraunhofer Institute for Machine Tools and Forming Technology (Author)
  • Steffen Ihlenfeldt - , Chair of Machine Tools Development and Adaptive Controls, Fraunhofer Institute for Machine Tools and Forming Technology (Author)
  • Günter Radons - , Chemnitz University of Technology (Author)

Abstract

We study mechanical vibrations in milling with non-uniform pitch and variable helix tools. The process is modeled by a periodic delay differential equation with distributed delay, which takes into account, for example, the nonlinear cutting force behavior, the effect of runout, and the exact delay distribution due to the unequally spaced flutes. We present a new method for the identification of the chatter stability lobes from the linearized system that is based on the multifrequency solution. We give detailed remarks on the truncation of the resulting infinite dimensional matrices and the efficient numerical implementation of the method. Cutting tests for steel milling with a customary end mill with non-uniform pitch and variable helix angle and a conventional end mill with uniform pitch and constant helix angle are performed. The numerical and experimental results coincide well. They reveal a significant increase of the limiting depth of cut for the variable helix tool compared to the conventional tool. Moreover, we show that in contrast to conventional tools, for non-uniform pitch and variable helix tools, an exact model with time-varying coefficients, nonlinear cutting force behavior, and runout is necessary for an accurate prediction of the stability lobes.

Details

Original languageEnglish
Pages (from-to)2613-2625
Number of pages13
JournalInternational Journal of Advanced Manufacturing Technology
Volume89
Issue number9-12
Publication statusPublished - 1 Apr 2017
Peer-reviewedYes

Keywords

Keywords

  • Chatter, Milling, Non-uniform pitch, Stability, Variable helix, Vibration