Volume 1 Issue 3
May  2021
Turn off MathJax
Article Contents
Xuebin DANG, Min WAN, Yun YANG. Prediction and suppression of chatter in milling of structures with low-rigidity: A review[J]. Journal of Advanced Manufacturing Science and Technology , 2021, 1(3): 2021010. doi: 10.51393/j.jamst.2021010
Citation: Xuebin DANG, Min WAN, Yun YANG. Prediction and suppression of chatter in milling of structures with low-rigidity: A review[J]. Journal of Advanced Manufacturing Science and Technology , 2021, 1(3): 2021010. doi: 10.51393/j.jamst.2021010

Prediction and suppression of chatter in milling of structures with low-rigidity: A review

doi: 10.51393/j.jamst.2021010
Funds:

This research has been supported by the National Natural Science Foundation of China under Grant no. 51975481.

  • Received Date: 2021-04-01
  • Rev Recd Date: 2021-05-05
  • Available Online: 2021-07-26
  • Publish Date: 2021-07-26
  • Milling is widely used to machine the structures with low-rigidity in astronautic and aeronautic industries, while chatter vibration, which is a great limitation and a serious problem, is easy to occur in this kind of process due to the weak stiffness of the structures. To solve the machining problems caused by chatter, prediction and suppression are two important methods that are commonly used by researchers and industry engineers. This article reviews the study progresses on the prediction and suppression of the chatter occurring in milling process of the low-rigidity structure. The dynamic model, acquisition of dynamic parameters, and suppression techniques are introduced. Besides, the problems and the outlooks of the future coming research are also given in the conclusions.

  • loading
  • [1]
    . Herranz S, Campa FJ, Lacalle Lopez de LN, et al. The milling of airframe components with low rigidity:A general approach to avoid static and dynamic problems. Proceeding of the Institution of Mechanical Engineers, Part B:Journal of Engineering Manufacture 2005; 219:789-801.
    [2]
    . Itoh M, Hayasaka T, Shamoto E. High-efficiency smooth-surface high-chatter-stability machining of thin plates with novel face-milling cutter geometry. Precision Engineering 2020; 64:165-176.
    [3]
    . Jain AK, Narasaiah K, Gopinath S. Machining of thin walls and thin floor aerospace components made of aluminum alloy with high aspect ratio. Materials Science Forum 2015; 830-831:112-115.
    [4]
    . Balon P, Rejman E, Smusz R, et al. Implementation of high speed machining in thin-walled aircraft integral elements. De Gruyter 2018; 8:162-169.
    [5]
    . Wimmer S, Hunyadi P, Zaeh MF. A numerical approach for the prediction of static surface errors in the peripheral milling of thin-walled structures. Production Engineering 2019; 13:479-488.
    [6]
    . Del Sol I, Rivero A, Lacalle Lopez de LN, et al. Thin-wall machining of light alloys:A review of models and industrial approaches. Materials 2019; 12:1-28.
    [7]
    . Davies MA, Balachandran B. Impact dynamics in milling of thin-walled structures. Nonlinear Dynamics 2000; 22:375-392.
    [8]
    . Thevenot V, Arnaud L, Dessein G, et al. Influence of material removal on the dynamic behavior of thinwalled structures in peripheral milling. Machining Science and Technology 2007; 10:275-287.
    [9]
    . Song QH, Ai X, Tang WX. Prediction of simultaneous dynamic stability limit of time-variable parameters system in thin-walled workpiece highspeed milling process. International Journal of Advanced Manufacturing Technology 2011; 55:883-889.
    [10]
    . Adetoro OB, Sim WM, Wen PH. An improved prediction of stability lobes using nonlinear thin wall dynamics. Journal of Materials Processing Technology 2010; 210:969-979.
    [11]
    . Sun YW, Jiang SL. Predictive modeling of chatter stability considering force-induced deformation effect in milling thin-walled parts. International Journal of Machine Tools and Manufacture 2018; 135:38-52.
    [12]
    . Wan M, Dang XB, Zhang WH, et al. Optimization and improvement of stable processing condition by attaching additional masses for milling of thin-walled workpiece. Mechanical Systems and Signal Processing 2018; 103:196-215.
    [13]
    . Quintana G, Ciurana J. Chatter in machining processes:A review. International Journal of Machine Tools and Manufacture 2011; 51:363-376.
    [14]
    . Dang XB, Wan M, Zhang WH, et al. Chatter analysis and mitigation of milling of the pocket-shaped thin-walled workpieces with viscous fluid. International Journal of Mechanical Sciences 2021; 194:106214.
    [15]
    . Altintas Y. Manufacturing automation:Metal cutting mechanics, machine tool vibrations, and CNC design. New York:Cambridge University Press, 2012.
    [16]
    . Taylor F. On the art of cutting metal. Transactions ASME 1907; 28:221-250.
    [17]
    . Tobias SA, Fishwick W. Theory of regenerative machine tool chatter. Engineer 1958; 205:199-203.
    [18]
    . Altintas Y, Budak E. Analytical prediction of stability lobes in milling. CIRP Annals-Manufacturing Technology 1995; 44:357-362.
    [19]
    . Insperger T, Stepan G. Semi-discretization method for delayed systems. International Journal for Numerical Methods in Engineering 2002; 55:503-518.
    [20]
    . Munoa J, Beudaert X, Dombovari Z, et al. Chatter suppression techniques in metal cutting. CIRP AnnalsManufacturing Technology 2016; 65:785-808.
    [21]
    . Zhu LD, Liu CF. Recent progress of chatter prediction, detection and suppression in milling. Mechanical Systems and Signal Processing 2020; 143:106840.
    [22]
    . Smith S, Dvorak D. Tool path strategies for high speed milling aluminum workpieces with thin webs. Mechatronics 1998; 8:291-300.
    [23]
    . Song QH, Liu ZQ, Wan Y, et al. Application of sherman-morrison-woodbury formulas in instantaneous dynamic of peripheral milling for thinwalled component. International Journal of Mechanical Sciences 2015; 96-97:79-90.
    [24]
    . Seguy S, Campa FJ, Lacalle Lopez de LN, et al. Toolpath dependent stability lobes for the milling of thin-walled workpiece. International Journal of Machining and Machinability Materials 2008; 4:377-392.
    [25]
    . Tunc LT, Zatarain M. Stability optimal selection of stock shape and tool axis in finishing of thin-wall parts. CIRP Annals-Manufacturing Technology 2019; 68(1):401-404.
    [26]
    . Kiran K, Kayacan MC. Cutting force modeling and accurate measurement in milling of flexible workpieces. Mechanical Systems and Signal Processing 2019; 133:106284.
    [27]
    . Eksioglu C, Kilic ZM, Altintas Y. Discrete-time prediction of chatter stability, cutting forces, and surface location errors in flexible milling systems. Journal of Manufacturing Science and Engineering 2012; 134:061006.
    [28]
    . Campa FJ, Lacalle Lopez de LN, Celaya A. Chatter avoidance in the milling of thin floors with bull-nose end mills:Model and stability diagrams. International Journal of Machine Tools and Manufacture 2011; 51:43-53.
    [29]
    . Yang YQ, Liu Q, Zhang B. Three-dimensional chatter stability prediction of milling based on the linear and exponential cutting force model. International Journal of Advanced Manufacturing Technology 2014; 72:1175-1185.
    [30]
    . Yan R, Gong YH, Peng FY, et al. Three degrees of freedom stability analysis in the milling with bullnosed end mills. International Journal of Advanced Manufacturing Technology 2016; 86:71-85.
    [31]
    . Fei JX, Lin B, Yan S, et al. Chatter prediction for milling of flexible pocket-structure. International Journal of Advanced Manufacturing Technology 2017; 89:2721-2730.
    [32]
    . Powalka B, Jemielniak K. Stability analysis in milling of flexible parts based on operational modal analysis. CIRP Journal of Manufacturing Science and Technology 2015; 9:125-135.
    [33]
    . Fei JX, Xu FF, Lin B, et al. State of the art in milling process of the flexible workpiece. International Journal of Advanced Manufacturing Technology 2020; 109:1695-1725.
    [34]
    . Yue CX, Gao HN, Liu XL, et al. A review of chatter vibration research in milling. Chinese Journal of Aeronautics 2019; 32(2):215-242.
    [35]
    . Thevenot V, Arnaud L, Dessein G, et al. Integration of dynamic behaviour variations in the stability lobes method:3d lobes construction and application to thinwalled structure milling. International Journal of Advanced Manufacturing Technology 2006; 27:638-644.
    [36]
    . Biermann D, Kersting P, Surmann T. A general approach to simulating workpiece vibrations during five-axis milling of turbine blades. CIRP AnnalsManufacturing Technology 2010; 59(1):125-128.
    [37]
    . Campa FJ, Lacalle Lopez de LN, Urbicain G, et al. Critical thickness and dynamic stiffness for chatter avoidance in thin floors milling. Advanced Materials Research 2011; 188:116-121.
    [38]
    . Budak E, Tunc LT, Alan S, et al. Prediction of workpiece dynamics and its effects on chatter stability in milling. CIRP Annals-Manufacturing Technology 2012; 61:339-342.
    [39]
    . Yang Y, Zhang WH, Ma YC, et al. Chatter stability prediction for the peripheral milling of thin-walled workpieces with curved surfaces. International Journal of Machine Tools and Manufacture 2016; 109:36-48.
    [40]
    . Dang XB, Wan M, Yang Y, et al. Efficient prediction of varying dynamic characteristics in thinwall milling using freedom and mode reduction methods. International Journal of Mechanical Sciences 2019; 150:202-216.
    [41]
    . Ahmadi K. Finite strip modeling of the varying dynamics of thin-walled pocket structures during machining. International Journal of Advanced Manufacturing Technology 2017; 89:2691-2699.
    [42]
    . Tuysuz O, Altintas Y. Frequency domain updating of thin-walled workpiece dynamics using reduced order substructuring method in machining. Journal of Manufacturing Science and Engineering 2017; 139:071013.
    [43]
    . Tuysuz O, Altintas Y. Time domain modeling of varying dynamic characteristics in thin-wall machining using perturbation and reduced order substructuring methods. Journal of Manufacturing Science and Engineering 2018; 14:011015.
    [44]
    . Tuysuz O. Modeling of machining thin-walled aerospace structures[dissertation]. Vancouver:The University of British Columbia, 2018.
    [45]
    . Yang Y, Zhang WH, Ma YC, et al. An efficient decomposition-condensation method for chatter prediction in milling large-scale thin-walled structures. Mechanical Systems and Signal Processing 2019; 121:58-76.
    [46]
    . Kersting P, Biermann D. Modeling workpiece dynamics using sets of decoupled oscillator models. Machining Science and Technology 2012; 16:564-579.
    [47]
    . Bravo U, Altuzarra O, Lacalle LN, et al. Stability limits of milling considering the flexibility of the workpiece and the machine. International Journal of Machine Tools and Manufacture 2005; 45:1669-1680.
    [48]
    . Budak E, Altintas Y. Analytical prediction of chatter stability in milling, Part I:General formulation. Journal of Dynamics Systems Measurement and Control 1998; 120:351-36.
    [49]
    . Merdol S, Altintas Y. Multi frequency solution of chatter stability for low immersion milling. Transactions of the ASME-Journal of Manufacturing Science and Engineering 2004; 126(3):459-466.
    [50]
    . Ding Y, Zhu LM, Zhang XJ, et al. A fulldiscretization method for prediction of milling stability. International Journal of Machine Tools and Manufacture 2010; 50:502-509.
    [51]
    . Li WT, Wang LP, Yu G. An accurate and fast milling stability prediction approach based on the newton-cotes rules. International Journal of Mechanical Sciences 2020; 177:105469.
    [52]
    . Insperger T, Munoa J, Zatarain M, et al. Unstable islands in the stability chart of milling processes due to the helix angle. CIRP 2nd International Conference on High Performance Cutting. 2006.p.12-13.
    [53]
    . Patel BR, Mann B, Young K. Uncharted islands of chatter instability in milling. International Journal of Machine Tools and Manufacture 2008; 48:124-134.
    [54]
    . Merdol S, Altintas Y. Mechanics and dynamics of serrated cylindrical and tapered end mills. Journal of Manufacturing Science and Engineering 2004; 126:317-326.
    [55]
    . Tehranizadeh F, Koca R, Budak E. Investigating effects of serration geometry on milling forces and chatter stability for their optimal selection. International Journal of Machine Tools and Manufacture 2019; 144:103425.
    [56]
    . Wan M, Zhang WH, Dang JW, et al. A unified stability prediction method for milling process with multiple delays. International Journal of Machine Tools and Manufacture 2010; 50(1):29-41.
    [57]
    . Altintas Y, Engin S, Budak E. Analytical stability prediction and design of variable pitch cutters. Transactions of the ASME-Journal of Manufacturing Science and Engineering 1999; 121:173-178.
    [58]
    . Budak E. An analytical design method for milling cutters with nonconstant pitch to increase stability, Part II:Theory. Journal of Manufacturing Science and Engineering 2003; 125:29-34.
    [59]
    . Budak E. An analytical design method for milling cutters with nonconstant pitch to increase stability, part ii:Application. Journal of Manufacturing Science and Engineering 2003; 125:35-38.
    [60]
    . Sims ND, Mann B, Huyanan S. Analytical prediction of chatter stability for variable pitch and variable helix milling tools. Journal of Sound and Vibration 2008; 317:664-686.
    [61]
    . Sisson TR, Kegg RL. An explanation of low-speed chatter effects. Transactions of ASME Journal of Engineering for Industry 1969; 91:951-958.
    [62]
    . Tlusty J. Analysis of the state of research in cutting dynamics. Annals of the CIRP 1978; 27:583-589.
    [63]
    . Tlusty J, Ismail F. Special aspects of chatter in milling. Transactions of ASME Journal of Vibration, Acoustics, Stress, and Reliability in Design 1983; 105:24-32.
    [64]
    . Yusoff AR, Turner S, Taylor C, et al. The role of tool geometry in process damped milling. International Journal of Advanced Manufacturing Technology 2010; 50:883-895.
    [65]
    . Tunc L, Budak E. Effect of cutting conditions and tool geometry on process damping in machining. International Journal of Machine Tools and Manufacture 2012; 57:10-19.
    [66]
    . Feng J, Wan M, Gao TQ, et al. Mechanism of process damping in milling of thin-walled workpiece. International Journal of Machine Tools and Manufacture 2018; 134:1-19.
    [67]
    . Kolluru K, Axinte D, Becker A. A solution for minimising vibrations in milling of thin walled casings by applying dampers to workpiece surface. CIRP Annals-Manufacturing Technology 2013; 62:415-418.
    [68]
    . Kolluru K, Axinte D, Raffles M, et al. Vibration suppression and coupled interaction study in milling of thin wall casings in the presence of tuned mass dampers. Proceedings of the Institution of Mechanical Engineers Part B:Journal of Engineering Manufacture 2014; 228:826-836.
    [69]
    . Kolluru K, Axinte D. Novel ancillary device for minimizing machining vibrations in thin wall assemblies. International Journal of Machine Tools and Manufacture 2014; 85:79-86.
    [70]
    . Shi JH, Song QH, Liu ZQ, et al. Partial surface damper to suppress vibration for thin walled plate milling. Chinese Journal of Mechanical Engineering 2017; 30:632-643.
    [71]
    . Ma JJ, Zhang DH, Wu BH, et al. Stability improvement and vibration suppression of the thinwalled workpiece in milling process via magnetorheological fluid flexible fixture. International Journal of Advanced Manufacturing Technology 2017; 88:1231-1242.
    [72]
    . Zhang Z, Li HG, Meng G, et al. Milling chatter suppression in viscous fluid:A feasibility study. International Journal of Machine Tools and Manufacture 2017; 120:20-26.
    [73]
    . Zhang Z, Li HG, Liu XB, et al. Chatter mitigation for the milling of thin-walled workpiece. International Journal of Mechanical Sciences 2018; 138-139:262-271.
    [74]
    . Wang SQ, He CL, Li JG, et al. Vibration-free surface finish in the milling of a thin-walled cavity part using a corn starch suspension. Journal of Materials Processing Technology 2021; 290:116980.
    [75]
    . Aoyama T, Kakinuma Y. Development of fixture devices for thin and compliant workpieces. CIRP Annals-Manufacturing Technology, 2005, 54:325-328.
    [76]
    . Zeng SS, Wan XJ, Li WL, et al. A novel approach to fixture design on suppressing machining vibration of flexible workpiece. International Journal of Machine Tools and Manufacture 2012; 58:29-43.
    [77]
    . Wan XJ, Zhang Y. A novel approach of fixture layout optimization on maximizing dynamic machinability. International Journal of Machine Tools and Manufacture 2013; 70:32-44.
    [78]
    . Wan XJ, Zhang Y, Huang XD. Investigation of influence of fixture layout on dynamic response of thin-wall multi-framed work-piece in machining. International Journal of Machine Tools and Manufacture 2013; 75:87-99.
    [79]
    . Matsubara A, Taniyama Y, Wang J, et al. Design of a support system with a pivot mechanism for suppressing vibrations in thin-wall milling. CIRP Annals-Manufacturing Technology 2017; 66:381-384.
    [80]
    . Fei JX, Lin B, Yan S, et al. Chatter mitigation using moving damper. Journal of Sound and Vibration 2017; 410:49-63.
    [81]
    . Fei JX, Lin B, Xiao JL, et al. Investigation of moving fixture on deformation suppression during milling process of thin-walled structures. Journal of Manufacturing Processes 2018; 32:403-411.
    [82]
    . Ozturk E, Barrios A, Sun C, et al. Robotic assisted milling for increased productivity. CIRP AnnalsManufacturing Technology 2018; 67:427-430.
    [83]
    . Barrios A, Mata S, Fernandez A, et al. Frequency response prediction for robot assisted machining. MM Science Journal 2019; 4:3099-3106.
    [84]
    . Smith S, Wilhelm R, Dutterer B, et al. Sacrificial structure preforms for thin part machining. CIRP Annals-Manufacturing Technology 2012; 61:379-382.
    [85]
    . Munoa J, Sanz-Calle M, Dombovari Z, et al. Tuneable clamping table for chatter avoidance in thinwalled part milling. CIRP Annals-Manufacturing Technology 2020; 69(1):313-316.
    [86]
    . Munoa J, Beudaert X, Erkorkmaz K, et al. Active suppression of structural chatter vibrations using machine drives & accelerometers. CIRP Annals 2015; 64(1):385-388.
    [87]
    . Monnin J, Kuster F, Wegener K. Optimal control for chatter mitigation in milling-Part 1:Modeling & control design. Control Engineering Practice 2014; 24:156-166.
    [88]
    . Abele E, Hanselka H, Haase F, et al. Development & design of an active work piece holder driven by piezo actuators. Production Engineering 2008; 2(4):437-442
    [89]
    . Brecher C, Manoharan D, Ladra U, et al. Chatter suppression with an active workpiece holder. Production Engineering 2010; 4(2-3):239-245.
  • 加载中

Catalog

    通讯作者: 陈斌, bchen63@163.com
    • 1. 

      沈阳化工大学材料科学与工程学院 沈阳 110142

    1. 本站搜索
    2. 百度学术搜索
    3. 万方数据库搜索
    4. CNKI搜索

    Figures(1)

    Article Metrics

    Article views (723) PDF downloads(114) Cited by()
    Proportional views
    Related

    /

    DownLoad:  Full-Size Img  PowerPoint
    Return
    Return