TY - JOUR
T1 - Coupled interaction of dynamic responses of tool and workpiece in thin wall milling
AU - Kolluru, K.
AU - Axinte, D.
N1 - Funding Information:
The authors would like to thank EPSRC and Rolls-Royce for providing the funding under Dorothy Hodgkin Postgraduate Award scholarship through grant number EP/P505917/1 to undertake this research. They would like to thank Mr Peter Winton of Rolls Royce and Dr Mark Raffles of Rolls Royce UTC at University of Nottingham for their support through discussions and reviews. Special thanks also go to Stuart Branston and Mark Daine of University of Nottingham for supporting all the experimental activities reported in this work.
PY - 2013
Y1 - 2013
N2 - Chatter free thin wall machining requires knowledge of the dynamics of a machine-tool system and workpiece either for designing damping solutions or for modelling impact dynamics. Previous studies on thin wall milling mostly focussed on stability studies. However studies on the interaction between the tool and workpiece responses in thin wall machining are scarce in the literature. In this work, the coupled dynamic response of tool and workpiece is presented both for an open (thin wall straight cantilever) and for closed (thin wall ring type casing) geometry structures. Experiments were carried out for different tool overhangs and depths of cut and the machining vibration signal was analysed in time-frequency domain to study the interaction, i.e. coupling, of tool-workpiece dynamic response at various cutting tooth engagement/idle times. The findings from this study highlight the importance of tool's frequency, particularly torsional and first bending modes, in impact dynamics of thin wall milling. Moreover, the differences in dynamic response interaction between a cutting tool and thin wall plate and a cylinder are identified. While the analysis of the open geometry structure showed the presence of tool and workpiece responses for any depth of cut, results on closed geometry structure exhibited a complete dominance of tool mode at higher depths of cut. These findings are of critical importance in understanding the impact dynamics in thin wall milling and also of effectiveness of passive damping solutions.
AB - Chatter free thin wall machining requires knowledge of the dynamics of a machine-tool system and workpiece either for designing damping solutions or for modelling impact dynamics. Previous studies on thin wall milling mostly focussed on stability studies. However studies on the interaction between the tool and workpiece responses in thin wall machining are scarce in the literature. In this work, the coupled dynamic response of tool and workpiece is presented both for an open (thin wall straight cantilever) and for closed (thin wall ring type casing) geometry structures. Experiments were carried out for different tool overhangs and depths of cut and the machining vibration signal was analysed in time-frequency domain to study the interaction, i.e. coupling, of tool-workpiece dynamic response at various cutting tooth engagement/idle times. The findings from this study highlight the importance of tool's frequency, particularly torsional and first bending modes, in impact dynamics of thin wall milling. Moreover, the differences in dynamic response interaction between a cutting tool and thin wall plate and a cylinder are identified. While the analysis of the open geometry structure showed the presence of tool and workpiece responses for any depth of cut, results on closed geometry structure exhibited a complete dominance of tool mode at higher depths of cut. These findings are of critical importance in understanding the impact dynamics in thin wall milling and also of effectiveness of passive damping solutions.
KW - Chatter
KW - Coupled dynamic response
KW - Thin wall machining
KW - Time-frequency analysis
UR - http://www.scopus.com/inward/record.url?scp=84876743039&partnerID=8YFLogxK
U2 - 10.1016/j.jmatprotec.2013.03.018
DO - 10.1016/j.jmatprotec.2013.03.018
M3 - Article
AN - SCOPUS:84876743039
SN - 0924-0136
VL - 213
SP - 1565
EP - 1574
JO - Journal of Materials Processing Technology
JF - Journal of Materials Processing Technology
IS - 9
ER -