Chatter, process damping, and chip segmentation in turning: A signal processing approach

An increasing number of aerospace components are manufactured from titanium and nickel alloys that are difficult to machine due to their thermal and mechanical properties. This limits the metal removal rates that can be achieved from the production process. However, under these machining conditions the phenomenon of process damping can be exploited to help avoid self-excited vibrations known as regenerative chatter. This means that greater widths of cut can be taken so as to increase the metal removal rate, and hence offset the cutting speed restrictions that are imposed by the thermo-mechanical properties of the material. However, there is little or no consensus as to the underlying mechanisms that cause process damping. The present study investigates two process damping mechanisms that have previously been proposed in the machining literature: the tool flank/workpiece interference effect, and the short regenerative effect. A signal processing procedure is employed to identify flank/workpiece interference from experimental data. Meanwhile, the short regenerative model is solved using a new frequency domain approach that yields additional insight into its stabilising effect. However, analysis and signal processing of the experimentally obtained data reveals that neither of these models can fully explain the increases in stability that are observed in practice. Meanwhile, chip segmentation effects were observed in a number of measurements, and it is suggested that segmentation could play an important role in the process-damped chatter stability of these materials

An experimental investigation of chatter effects on tool life

Tool wear is one of the most important considerations in machining operations as it affects surface quality and integrity, productivity and cost. The most commonly used model for tool life analysis is the one proposed by F.W. Taylor about a century ago. Although the extended form of this equation includes the effects of important cutting conditions on tool wear, tool life studies are mostly performed under stable cutting conditions where the effect of chatter vibrations are not considered. This paper presents an empirical attempt to understand tool life under vibratory cutting conditions. Tool wear data are collected in turning and milling on different work materials under stable and chatter conditions. The effects of cutting conditions as well as severity of chatter on tool life are analyzed. The results indicate significant reduction in tool life due to chatter as expected. They also show that the severity of chatter, and thus the vibration amplitude, strongly reduces the life of cutting tools. These results can be useful in evaluating the real cost of chatter by including the reduced tool life. They can also be useful in justifying the cost of chatter suppression and more rigid machining systems

The role of tool geometry in process damped milling

The complex interaction between machining structural systems and the cutting process results in machining instability, so called chatter. In some milling scenarios, process damping is a useful phenomenon that can be exploited to mitigate chatter and hence improve productivity. In the present study, experiments are performed to evaluate the performance of process damped milling considering different tool geometries (edge radius, rake and relief angles and variable helix/pitch). The results clearly indicate that variable helix/pitch angles most significantly increase process damping performance. Additionally, increased cutting edge radius moderately improves process damping performance, while rake and relief angles have a smaller and closely coupled effect

Entanglement dynamics of two qubits under the influence of external kicks and Gaussian pulses

We have investigated the dynamics of entanglement between two spin-1/2 qubits that are subject to independent kick and Gaussian pulse type external magnetic fields analytically as well as numerically. Dyson time ordering effect on the dynamics is found to be important for the sequence of kicks. We show that "almost-steady" high entanglement can be created between two initially unentangled qubits by using carefully designed kick or pulse sequences

Dynamics of Entanglement and Bell-nonlocality for Two Stochastic Qubits with Dipole-Dipole Interaction

We have studied the analytical dynamics of Bell nonlocality as measured by CHSH inequality and entanglement as measured by concurrence for two noisy qubits that have dipole-dipole interaction. The nonlocal entanglement created by the dipole-dipole interaction is found to be protected from sudden death for certain initial states

On the stability of high-speed milling with spindle speed variation

Spindle speed variation is a well-known technique to suppress regenerative machine tool vibrations, but it is usually considered to be effective only for low spindle speeds. In this paper, the effect of spindle speed variation is analyzed in the high-speed domain for spindle speeds corresponding to the first flip (period doubling) and to the first Hopf lobes. The optimal amplitudes and frequencies of the speed modulations are computed using the semidiscre- tization method. It is shown that period doubling chatter can effectively be suppressed by spindle speed variation, although, the technique is not effective for the quasiperiodic chatter above the Hopf lobe. The results are verified by cutting tests. Some special cases are also discussed where the practical behavior of the system differs from the predicted one in some ways. For these cases, it is pointed out that the concept of stability is understood on the scale of the principal period of the system—that is, the speed modulation period for variable spindle speed machining and the tooth passing period for constant spindle speed machining

Compliance error compensation in robotic-based milling

The paper deals with the problem of compliance errors compensation in robotic-based milling. Contrary to previous works that assume that the forces/torques generated by the manufacturing process are constant, the interaction between the milling tool and the workpiece is modeled in details. It takes into account the tool geometry, the number of teeth, the feed rate, the spindle rotation speed and the properties of the material to be processed. Due to high level of the disturbing forces/torques, the developed compensation technique is based on the non-linear stiffness model that allows us to modify the target trajectory taking into account nonlinearities and to avoid the chattering effect. Illustrative example is presented that deals with robotic-based milling of aluminum alloy

RAFT-based polystyrene and polyacrylate melts under thermal and mechanical stress

Although controlled/living radical polymerization processes have significantly facilitated the synthesis of well-defined low polydispersity polymers with specific functionalities, a detailed and systematic knowledge of the thermal stability of the products-highly important for most industrial processes-is not available. Linear polystyrene (PS) carrying a trithiocarbonate mid-chain functionality (thus emulating the structure of the Z-group approach via reversible addition-fragmentation chain transfer (RAFT) based macromolecular architectures) with various chain lengths (20 kDa ≤ Mn,SEC ≤ 150 kDa, 1.27 ≤ Crossed D sign = Mw/Mn ≤ 1.72) and chain-end functionality were synthesized via RAFT polymerization. The thermal stability behavior of the polymers was studied at temperatures ranging from 100 to 200 C for up to 504 h (3 weeks). The thermally treated polymers were analyzed via size exclusion chromatography (SEC) to obtain the dependence of the polymer molecular weight distribution on time at a specific temperature under air or inert atmospheres. Cleavage rate coefficients of the mid-chain functional polymers in inert atmosphere were deduced as a function of temperature, resulting in activation parameters for two disparate Mn starting materials (Ea = 115 ± 4 kJ·mol-1, A = 0.85 × 109 ± 1 × 109 s-1, M n,SEC = 21 kDa and Ea = 116 ± 4 kJ·mol -1, A = 6.24 × 109 ± 1 × 109 s-1, Mn,SEC = 102 kDa). Interestingly, the degradation proceeds significantly faster with increasing chain length, an observation possibly associated with entropic effects. The degradation mechanism was explored in detail via SEC-ESI-MS for acrylate based polymers and theoretical calculations suggesting a Chugaev-type cleavage process. Processing of the RAFT polymers via small scale extrusion as well as a rheological assessment at variable temperatures allowed a correlation of the processing conditions with the thermal degradation properties of the polystyrenes and polyacrylates in the melt. © 2013 American Chemical Society.C.B.-K and M.W. gratefully acknowledge financial support from the German Research Council (DFG). M.L.C gratefully acknowledges generous allocations of supercomputing time from the Australian National Computing Facility, financial support from the Australian Research Council (ARC) Centre of Excellence for Free-radical Chemistry and Biotechnology and an ARC Future Fellowship. C.B.-K. acknowledges additional funding from the Karlsruhe Institute of Technology (KIT) in the context of the Helmholtz programs

Determination of the steady state response of viscoelastically supported rectangular specially orthotropic plates with varying supported area

The influence of the amount of the supported area on the free and forced vibration properties of anisotropic plate is presented. Using the energy based finite difference method, the problem is modelled by a kind of finite difference element. Due to the significiance of the fundamental frequency of the plate, its variation was investigated with respect to the amount of the supported area on the plate, mechanical properties of plate material and translational spring coefficient of supports. The steady state response of viscoelastically supported plates was also investigated numerically for various damping coefficients and amounts of supported areas. Numerical results are obtained to investigate the effect of the ratio of the plate system. In the numerical examples, the natural frequency parameters and steady state responses to a sinusoidally varying force are assessed for the fundamental mode. Results showing effect of supported area ratios of plate indicate that variation of ratio of supported area of plate system is very significiant. Convergence studies are made. Many new results have been presented. Considered problems are solved within the frame work of Kirchhoff-Love hypothesis