Article
Engineering, Manufacturing
Huseyin Celikag, Erdem Ozturk, Neil D. Sims
Summary: This paper focuses on diagnosing mode coupling chatter in robotic milling and provides theoretical and experimental evidence that mode coupling chatter is not possible in milling operations. The results show that mode coupling chatter stability boundaries are very low and vaguely dependent on spindle speed, contradicting experimental observations. Therefore, it is concluded that the assumption of chip thickness depending only on current vibrations does not apply to milling operations, making mode coupling chatter in milling not possible.
INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE
(2021)
Article
Automation & Control Systems
Maojun Li, Dingxiao Huang, Xujing Yang
Summary: In high-speed robotic milling process, acoustic emission technique combined with root mean square value and fast Fourier transform method were used to analyze chatter phenomenon. A stability lobe diagram was proposed for predicting chatter occurrence, along with the establishment of underlying mechanism and theoretical analysis of chatter stability.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Mechanical
Jianghai Shi, Xiaoliang Jin, Hongrui Cao
Summary: In this study, the effects of rotating speed on the dynamic stiffness and damping coefficients of aerostatic journal bearing in micro-milling process were investigated. A method for calculating the stability lobe diagram (SLD) considering the speed effect was proposed. The effects of supply air pressure and air film thickness on SLD were comprehensively studied.
MECHANICAL SYSTEMS AND SIGNAL PROCESSING
(2022)
Article
Automation & Control Systems
Petr Petracek, Jiri Falta, Michal Stejskal, Ales Simunek, Petr Kupka, Matej Sulitka
Summary: This paper describes in detail an optimization procedure for the design of stock allowance distribution in Blisk blade machining to avoid chatter. The proposed method uses finite element analysis software to simulate the effects of material removal on workpiece dynamical properties, and couples it with a stability model based on the Jacobian of the cutting force. The experimental verification of the proposed method is also presented.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Manufacturing
Tony Schmitz
Summary: This paper presents a Type B analysis for stability uncertainty in milling, where the uncertainty is represented by offset boundaries based on user-selected uncertainties in spindle speed and axial depth. The geometric approach is demonstrated using a frequency domain stability solution for a selected milling system.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
Article
Automation & Control Systems
Yanqing Zhao, Kondo H. Adjallah, Alexandre Sava, Zhouhang Wang
Summary: This paper proposes an incipient chatter detection method that combines multiple sampling, data preprocessing, and a two-risk levels-based threshold. It effectively meets the time and reliability constraints of high dynamic applications and has been successfully applied in a digital high-speed milling process.
Article
Engineering, Manufacturing
Kai Guo, Yiran Zhang, Jie Sun
Summary: This paper introduces a new concept of active contact robotic milling, which improves the stability of robotic milling by actively controlling the force between the robot and the workpiece. This concept solves the limitations caused by the low rigidity of industrial robots in high-performance robotic milling. Experimental results validate the effectiveness of the concept, and a concise and effective framework is proposed to avoid milling vibrations, providing inspiration for future milling tool designs in flexible machine tool systems.
INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE
(2022)
Article
Engineering, Manufacturing
Bin Xiong, Yuan Wei, Dan Gu, Dongfang Zhao, Baoqiang Wang, Shulin Liu
Summary: This paper investigates the influence of milling cutter helix angle, radial immersion rate, and variable speed modulation coefficient on chatter suppression in milling process. The results show that the selection of milling cutters with different helix angles affects chatter stability, and variable speed milling can significantly suppress chatter.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE
(2021)
Article
Automation & Control Systems
Yanqing Zhao, Kondo H. Adjallah, Alexandre Sava, Zhouhang Wang
Summary: This paper presents a reliability model method based on maximum entropy features for real-time detection of early chatter in high-speed milling processes. By using the MSPR technique to collect data and calculating the standard deviation, the proposed method successfully detects various types of early chatter accurately.
Article
Engineering, Industrial
Faraz Tehranizadeh, Kaveh Rahimzadeh Berenji, Saltuk Yildiz, Erhan Budak
Summary: This study compares the effectiveness and performance of different cutting tools for suppressing chatter in milling thin-walled parts. Novel stability maps are generated to compare the performance of different cutting strategies in terms of productivity and surface finish quality. Experimental results demonstrate the superiority of crest-cut tools as a robust solution for overcoming chatter in thin-wall machining.
CIRP ANNALS-MANUFACTURING TECHNOLOGY
(2022)
Article
Automation & Control Systems
Ryong Paek, Song-Ho Ha, Sang-Chon Ri
Summary: Chatter in metal cutting can have negative effects such as poor surface quality, excessive tool wear, and waste of materials and energy. Researchers have been interested in spindle speed variation (SSV) as a method to suppress chatter. However, there has been limited research on determining more efficient signal types for chatter suppression. This study proposes a method that composes the spindle speed variation in multi-harmonic series using firefly algorithm (FA) to optimize the number, amplitudes, and modulating frequencies. The results show that composing the spindle speed variation signal in multiple harmonic series is reasonable for low fundamental frequencies, while a single harmonic term is sufficient for higher frequencies.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Manufacturing
Faraz Tehranizadeh, Kaveh Rahimzadeh Berenji, Erhan Budak
Summary: In drilling operations, improving cutting efficiency can be achieved by using crest-cut tools as an alternative method. Crest-cut tools introduce large stable regions at low-speed ranges due to their special geometry, enhancing stability limits and stable zones.
INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE
(2021)
Article
Automation & Control Systems
Ce Zhang, Changyou Li, Mengtao Xu, Guo Yao, Zhendong Liu, Weibing Dai
Summary: A simplified milling force model of ball-end milling cutter was established in this study, along with a nonlinear dynamic cutting force model and chatter vibration mechanical model with three degrees of freedom. The proposed models were experimentally verified, demonstrating their effectiveness in analyzing cutting force and chatter stability of ball-end milling cutters.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Manufacturing
Oier Franco, Xavier Beudaert, Alex Iglesias, Zoltan Dombovari, Kaan Erkorkmaz, Jokin Munoa
Summary: This paper investigates the structural chatter vibrations in large machine tool applications and emphasizes the importance of accurate dynamic characterization for predicting stability lobes. The study optimizes the tool radial engagement using the sweep milling force excitation method and proposes an alternative spectra computation technique to improve the signal to noise ratio. The receptance measurement is demonstrated using time domain simulations and applied in a large-scale three axis machining centre, resulting in more accurate stability boundary predictions.
INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE
(2022)
Article
Chemistry, Multidisciplinary
Markel Sanz-Calle, Zoltan Dombovari, Jokin Munoa, Alexander Iglesias, Luis Norberto Lopez de Lacalle
Summary: This paper proposes a semi-active tuneable clamping table (TCT) based on mode tuning for blade machining, which aims to avoid specific stiffening fixtures for each blade geometry. The device utilizes a self-tuning algorithm to optimize tuning for the measured chatter frequency, resulting in maximized chatter suppression capabilities.
APPLIED SCIENCES-BASEL
(2021)
Article
Engineering, Industrial
J. Munoa, M. Sanz-Calle, Z. Dombovari, A. Iglesias, J. Pena-Barrio, G. Stepan
CIRP ANNALS-MANUFACTURING TECHNOLOGY
(2020)
Article
Engineering, Manufacturing
H. Gonzalez, O. Pereira, L. N. Lopez de Lacalle, A. Calleja, I. Ayesta, J. Munoa
Summary: This paper introduces a method of machining Ti6Al4V integral blade rotors using CO2 as a cryogenic cooler, presenting a new proprietary cooling and lubrication technique to address issues with traditional oil emulsions. By balancing technical and environmental considerations, problems related to the reactivity of Ti6Al4V alloy with PCD tools have been successfully avoided.
JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME
(2021)
Article
Chemistry, Multidisciplinary
Markel Sanz-Calle, Zoltan Dombovari, Jokin Munoa, Alexander Iglesias, Luis Norberto Lopez de Lacalle
Summary: This paper proposes a semi-active tuneable clamping table (TCT) based on mode tuning for blade machining, which aims to avoid specific stiffening fixtures for each blade geometry. The device utilizes a self-tuning algorithm to optimize tuning for the measured chatter frequency, resulting in maximized chatter suppression capabilities.
APPLIED SCIENCES-BASEL
(2021)
Article
Engineering, Mechanical
David Lehotzky, Iker Mancisidor, Jokin Munoa, Zoltan Dombovari
Summary: This paper derives a novel mathematical model that considers the internal dynamics of the actuator, measuring device, and discrete filtering, in order to formulate a more realistic model for milling processes assisted by active damping. The study shows that accurate stability prediction requires the incorporation of actuator and filter dynamics into the model, especially at high spindle speeds and large feedback gains.
JOURNAL OF COMPUTATIONAL AND NONLINEAR DYNAMICS
(2022)
Article
Engineering, Mechanical
M. Gil, X. Beudaert, J. Munoa, D. Barrenetexea, J. A. Sanchez
Summary: This study aims to identify the origin of surface topography defects in machining processes by correlating vibration and process parameter measurements with profile measurements. Different analyses are applied to temporal signals such as vibrations and geometric signals obtained from the workpiece micro-geometry. The diagnostic method is successfully applied in various machining operations such as turning and grinding, validating its effectiveness in identifying topography defects.
MM SCIENCE JOURNAL
(2021)
Article
Engineering, Mechanical
D. Plakhotnik, A. Curutiu, A. Zhulavskyi, Xavier Beudaert, Jokin Munoa, M. Stautner
Summary: This paper elaborates on the use of digital twin concept in digital machining, aiming to combine digital representations of different objects involved in the machining process and provide practical recommendations. The framework supports a simulation layer that provides interaction data, which can be used for CAM simulation and NC verification.
MM SCIENCE JOURNAL
(2021)
Article
Engineering, Mechanical
M. Sanz-Calle, J. Munoa, A. Iglesias, L. N. Lopez de Lacalle, Z. Dombovari
Summary: This paper discusses the impact of radial engagement and number of flutes on flip stability in thin-walled milling, comparing up- and down-milling strategies. While it is possible to minimize flip likelihood, completely eliminating period-doubling chatter can only be achieved by tuning the cutter helix. The study validates results through semidiscretisation simulations.
MM SCIENCE JOURNAL
(2021)
Article
Engineering, Industrial
A. Astarloa, T. Semm, I. Mancisidor, M. H. Fernandes, J. Ellinger, Z. Dombovari, J. Munoa
Summary: Chatter vibrations originating from the machine structure limit the productivity of ram based machines performing heavy duty operations. The use of hydrostatic guideways can provide 3-4 times more damping compared to roller-based systems, but the introduction of active damping is a game changer, enhancing damping by more than 30 times.
CIRP ANNALS-MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Industrial
O. Franco, X. Beudaert, K. Erkorkmaz, J. Munoa
Summary: This paper studies the impact of guideway friction on TCP dynamics and proposes experimental and testing methods for more accurate characterization of TCP receptance and chatter stability predictions.
CIRP ANNALS-MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Manufacturing
Oier Franco, Xavier Beudaert, Alex Iglesias, Zoltan Dombovari, Kaan Erkorkmaz, Jokin Munoa
Summary: This paper investigates the structural chatter vibrations in large machine tool applications and emphasizes the importance of accurate dynamic characterization for predicting stability lobes. The study optimizes the tool radial engagement using the sweep milling force excitation method and proposes an alternative spectra computation technique to improve the signal to noise ratio. The receptance measurement is demonstrated using time domain simulations and applied in a large-scale three axis machining centre, resulting in more accurate stability boundary predictions.
INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE
(2022)
Review
Engineering, Mechanical
Alexander Iglesias, L. Taner Tunc, Orkun Ozsahin, Oier Franco, Jokin Munoa, Erhan Budak
Summary: An accurate characterization of machine dynamics is crucial for describing its dynamic response and predicting cutting stability. However, current conventional methods are often unreliable, leading to the development of alternative experimental methods to improve data quality.
MECHANICAL SYSTEMS AND SIGNAL PROCESSING
(2022)
Article
Engineering, Manufacturing
Asier Astarloa, Alptunc Comak, Iker Mancisidor, Maria Helena Fernandes, Jokin Munoa, Zoltan Dombovari
Summary: This study proposes using mode coupling effect to increase damping, stabilize the machining process, and optimize tool length and material to improve cutting stability in boring operations.
CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY
(2022)
Article
Engineering, Industrial
Erhan Budak, Atsushi Matsubara, Alkan Donmez, Jokin Munoa
Summary: This paper reviews the current state, challenges, and improvements in machine tool structural interfaces, including mechanical and thermal characteristics, geometric accuracy and precision, and wear and failure mechanisms. It also presents advanced modeling methods and health monitoring techniques.
CIRP ANNALS-MANUFACTURING TECHNOLOGY
(2022)
Proceedings Paper
Computer Science, Information Systems
Amaia Arregi, Inaki Inza, Inigo Bediaga
Summary: This paper proposes a data-driven methodology based on spectral data for early detection of failure in rotary components. The vibration-related data is transformed to the frequency domain, and a severity feature is calculated from the spectra. A prediction model is trained based on the relationship between this feature and production condition variables. The proposed method is validated using monitored data from a paper mill machine, and it is found to be effective in predicting failure in rotary components.
DATABASE AND EXPERT SYSTEMS APPLICATIONS, DEXA 2022 WORKSHOPS
(2022)
Article
Engineering, Multidisciplinary
Miriam Ugarte Querejeta, Leire Etxeberria Elorza, Goiuria Sagardui Mendieta, Gorka Unamuno Eguren, Inigo Bediaga Escudero
Summary: This paper presents one of the first empirical surveys in the industry on the challenges and current practices of virtual commissioning, especially in the machine tool manufacturing sector. The survey shows that virtual commissioning can significantly reduce commissioning time, error rate, and costs, but industry is still facing difficulties in integrating these new technologies.
