Hostname: page-component-78c5997874-g7gxr Total loading time: 0 Render date: 2024-11-15T19:19:01.165Z Has data issue: false hasContentIssue false
  • English
  • Français

Analytical Prediction of Stability Lobes for Passively Damped Boring Bars

Published online by Cambridge University Press:  15 May 2017

M. Fallah  and
B. Moetakef-Imani
M. Fallah
Affiliation:
Department of Mechanical EngineeringFerdowsi University of MashhadMashhad, Iran
B. Moetakef-Imani*
Affiliation:
Department of Mechanical EngineeringFerdowsi University of MashhadMashhad, Iran
*
*Corresponding author ([email protected])
Get access

Abstract

The present article proposes the closed-form solution for analytical prediction of stability lobes in internal turning process. The passively damped boring bar is modeled as a cantilevered Euler-Bernoulli beam with constant cross sectional properties in which a Tuned Mass Damper (TMD) is embedded for the purpose of chatter suppression. The non-dimensional equations of motion are derived, assuming that the boring bar dynamics is well-represented by the fundamental mode of vibration. The stability of equivalent two-DOF dynamic model, i.e. boring bar with TMD, is analyzed in frequency domain. The closed- form expressions for critical depth of cut and spindle speed are presented in terms of boring bar and TMD characteristics. The proposed solution considers the effects of boring bar's structural damping and cutting geometry of insert on the stability behavior of passively damped cutting tool. An unconstrained optimization method is utilized to compute the most optimal set of tuning parameters for anti-chatter TMD. In order to improve the boundary of stability in a global sense, maximization of minimum critical depth of cut is selected as the objective of optimization. The superior performance of anti-chatter TMD is compared to H∞ and H2 TMDs for a wide range of applications. Moreover, the achieved results show a remarkable improvement of stability boundary compared to recent research works.

Keywords

Stability improvementBoring barTuned mass damperAnti-chatter tuning
Type
Research Article
Information
Journal of Mechanics , Volume 33 , Issue 5 , October 2017 , pp. 641 - 654
Copyright
Copyright © The Society of Theoretical and Applied Mechanics 2017 

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

References

1. Quintana, G. and Ciurana, J., “Chatter in Machining Processes: A Review,” International Journal of Machine Tools and Manufacture, 51, pp. 363–376 (2011).CrossRefGoogle Scholar
2. Tlusty, J. G., Manufacturing Processes and Equipment, Prentice-Hall, New Jersey (2000).Google Scholar
3. Rivin, E. I. et al., “Tooling Structure: Interface between Cutting Edge and Machine Tool,” Journal of Manufacturing Technology, 49, pp. 591–634 (2000).Google Scholar
4. Eynian, M. and Altintas, Y., “Chatter Stability of General Turning Operations with Process Damping,” Journal of Manufacturing Science and Engineering, 131, 041005 (2009).CrossRefGoogle Scholar
5. Tarng, Y. S., Hseih, Y. W. and Li, T. C., “Automatic Selection of Spindle Speed for Suppression of Regenerative Chatter in Turning,” International Journal of Advanced Manufacturing Technology, 11, pp. 12–17 (1996).CrossRefGoogle Scholar
6. New, R. W. and Au, Y. H. J., “Chatter-Proof Overhang Boring Bars Stability Criteria and Design Procedure for a New Type of Damped Boring Bar,” Journal of Mechanical Design, 102, pp. 611–618 (1980).CrossRefGoogle Scholar
7. Houck, L., Schmitz, T. L. and Smith, K. S., “A Tuned Holder for Increased Boring Bar Dynamic Stiffness,” Journal of Manufacturing Processes, 13, pp. 24–29 (2011).CrossRefGoogle Scholar
8. Akesson, H., Smirnova, T. and Hakansson, L., “Analysis of Dynamic Properties of Boring Bars Concerning Different Clamping Conditions,” Journal of Mechanical Systems and Signal Processing, 23, pp. 2629–2647 (2009).CrossRefGoogle Scholar
9. Nagano, S. et al., “Development of a Composite Boring Bar,” Journal of Composite Structures, 38, pp. 531–539 (1997).CrossRefGoogle Scholar
10. Lee, D. G., Hwang, H. Y. and Kim, J. K., “Design and Manufacture of a Carbon Fiber Epoxy Rotating Boring Bar,” Journal of Composite Structures, 60, pp. 115–124 (2003).CrossRefGoogle Scholar
11. Rivin, E. I., Kang, H. L. and Kops, L., “Improving Dynamic Performance of Cantilever Boring Bars,” Journal of Manufacturing Technology, 38, pp. 377–380 (1989).Google Scholar
12. Tarng, Y. S., Kao, J. Y., and Lee, E. C., “Chatter Suppression in Turning Operations with a Tuned Vibration Absorber,” Journal of Materials Processing Technology, 105, pp. 55–60 (2000).CrossRefGoogle Scholar
13. Lee, E. C., Nian, C. Y. and Tarng, Y. S., “Design of a Dynamic Vibration Absorber Against Vibrations in Turning Operations,” Journal of Materials Processing Technology, 108, pp. 278–285 (2001).CrossRefGoogle Scholar
14. Wang, M., Zan, T., Yang, Y. and Fei, R., “Design and Implementation of Nonlinear TMD for Chatter Suppression: An Application in Turning Processes,” International Journal of Machine Tools and Manufacture, 50, pp. 474–479 (2010).CrossRefGoogle Scholar
15. Yang, Y., Munoa, J. and Altintas, Y., “Optimization of Multiple Tuned Mass Dampers to Suppress Machine Tool Chatter,” International Journal of Machine Tools and Manufacture, 50, pp. 834–842 (2010).CrossRefGoogle Scholar
16. Ema, S. and Marui, E., “Suppression of Chatter Vibration of Boring Tools using Impact Dampers,” International Journal of Machine Tools and Manufacture, 40, pp. 1141–1156 (2000).Google Scholar
17. Wang, M. and Fei, R., “Chatter Suppression Based on Nonlinear Vibration Characteristic of Electrorheological Fluid,” International Journal of Machine Tools and Manufacture, 39, pp. 1925–1934 (1999).CrossRefGoogle Scholar
18. Mei, D., Kong, T., Shih, A. J. and Chen, Z., “Magnetorheological Fluid-Controlled Boring Bar for Chatter Suppression,” Journal of Materials Processing Technology, 209, pp. 1861–1870 (2009).CrossRefGoogle Scholar
19. Min, B. K., O'Neal, G., Koren, Y. and Pasek, Z., “A Smart Boring Tool for Process Control,” Journal of Mechatronics, 12, pp. 1097–1114 (2002).CrossRefGoogle Scholar
20. Andren, L. and Hakansson, L., “Active Vibration Control of Boring Bar Vibrations,” Research Report No. 2004:07, Department of Signal Processing, Blekinge Institute of Technology, Sweden (2004).Google Scholar
21. Pratt, J. R., “Vibration Control for Chatter Suppression with Application to Boring Bars,” PhD Dissertation, Virginia Polytechnic Institute and State University, U.S.A. (1997).CrossRefGoogle Scholar
22. Pratt, J. R. and Nayfeh, A. H., “Chatter Control and Stability Analysis of a Cantilever Boring Bar under Regenerative Cutting Conditions,” Philosophical Transactions of the Royal Society Part A, 359, pp. 759–792 (2001).CrossRefGoogle Scholar
23. Chen, F., Lu, X. and Altintas, Y., “A Novel Magnetic Actuator Design for Active Damping of Machining Tools,” International Journal of Machine Tools and Manufacture, 85, pp. 58–69 (2014).Google Scholar
24. Glaser, D. J. and Nachtigal, C. L., “Development of a Hydraulic Chambered Actively Controlled Boring Bar,” Journal of Engineering for Industry, 101, pp. 362–368 (1979).CrossRefGoogle Scholar
25. Altintas, Y. and Weck, M., “Chatter Stability of Metal Cutting and Grinding,” Journal of Manufacturing Technology, 53, pp. 619–642 (2004).Google Scholar
26. Ray, J. C., “Damped Tuned Boring Bar,” US Patent 3447402 A (1969).Google Scholar
27. Holmen, H. K., “Adjustable Device for Damping Vibrations in Tool Holding Rods in Particular Boring Bar in Machine Tools,” US Patent 3598498 (1971).Google Scholar
28. Etling, S. A. and Stern, E. L., “Tunable Boring Bar for Suppressing Vibrations and Method Thereof,” US Patent 6443673 (2002).Google Scholar
29. Silent Tools Application Guide Catalog 2012, http://www.sandvik.coromant.com/sitecollectiondocuments/downloads/global/technicalguides/en-gb/c-1020-17.pdf (2012).Google Scholar
30. Den Hartog, J. P., Mechanical Vibrations, 4th Edition, McGraw-Hill, New York (1956).Google Scholar
31. Crandall, S. H. and Mark, W. D., Random Vibration in Mechanical Systems, Academic Press, New York (1963).Google Scholar
32. Asami, T., Nishihara, O. and Baz, A. M., “Analytical Solutions to H∞ and H2 Optimization of Dynamic Vibration Absorbers Attached to Damped Linear Systems,” Journal of Vibration and Acoustics, 124, pp. 284–295 (2002).CrossRefGoogle Scholar
33. Asami, T. and Nishihara, O., “Closed-Form Exact Solution to H∞ Optimization of Dynamic Vibration Absorbers (Application to Different Transfer Functions and Damping Systems),” Journal of Vibration and Acoustics, 125, pp. 398–405 (2003).CrossRefGoogle Scholar
34. Tlusty, J. and Polacek, M., “The Stability of Machine Tools Against Self-Excited Vibrations in Machining,” ASME International Research in Production Engineering, 1, pp. 465–474 (1963).Google Scholar
35. Nakano, Y., Takahara, H. and Kondo, E., “Countermeasure against Chatter in End Milling Operations using Multiple Dynamic Absorbers,” Journal of Sound and Vibration, 332, pp. 1626–1638 (2013).CrossRefGoogle Scholar
36. Yang, Y., Dai, W. and Liu, Q., “Design and Implementation of Two-Degree-of-Freedom Tuned Mass Damper in Milling Vibration Mitigation,” Journal of Sound and Vibration, 335, pp. 78–88 (2015).CrossRefGoogle Scholar
37. Rivin, E. I. and Kang, H. L., “Enhancement of Dynamic Stability of Cantilever Tooling Structures,” International Journal of Machine Tools and Manufacture, 32, pp. 539–561 (1992).CrossRefGoogle Scholar
38. Sims, N. D., “Vibration Absorbers for Chatter Suppression: A New Analytical Tuning Methodology,” Journal of Sound and Vibration, 301, pp. 592–607 (2007).CrossRefGoogle Scholar
39. Miguelez, M. H., Rubio, L., Loya, J. A. and Saez, J. F., “Improvement of Chatter Stability in Boring Operations with Passive Vibration Absorbers,” International Journal of Mechanical Science, 52, pp. 1376–1384 (2010).CrossRefGoogle Scholar
40. Altintas, Y., Manufacturing Automation, 2nd Edition, Cambridge University Press, Cambridge (2012).CrossRefGoogle Scholar
41. Nelder, J. and Mead, R., “A Simplex Method for Function Minimization,” The Computer Journal, 7, pp. 308–313 (1965).CrossRefGoogle Scholar
42. Rubio, L., Loya, J. A., Miguelez, M. H. and Saez, J. F., “Optimization of Passive Vibration Absorbers to Reduce Chatter in Boring,” Journal of Mechanical Systems and Signal Processing, 41, pp. 691–704 (2013).CrossRefGoogle Scholar
43. Kennametal Tooling Systems 2013 Master Catalog, http://www.kennametal.com/content/dam/kennametal/kennametal/common/Resources/Catalogs-Literature/Metalworking/ToolingSystemsMaster/A-12-02809_KMT_ToolingSystems2013_sectionM_Technical.pdf (2013).Google Scholar
44. Cheung, Y. L. and Wong, W. O., “H∞ Optimization of a Variant Design of the Dynamic Vibration Absorber Revisited and New Results,” Journal of Sound and Vibration, 330, pp. 3901–3912, (2011).CrossRefGoogle Scholar