Periodic cutting motions in a vibration-assisted, regenerative, nonlinear Orthogonal turning system

International Journal of Dynamics and Control - Tập 10 - Trang 1-12 - 2021
Siyuan Xing1, Albert C. J. Luo2
1Department of Mechanical Engineering, California Polytechnic State University, San Luis Obispo, USA
2Department of Mechanical and Industrial Engineering, Southern Illinois University Edwardsville, Edwardsville, USA

Tóm tắt

In this paper, a mathematical model of 2-degrees-of-freedom (2-DOF), vibration-assisted, regenerative, nonlinear orthogonal turning system is developed. The period-1 motions of such a system are predicted through the discrete mapping method. The discrete mapping is constructed by discretization of equations of motion of the machine-tool system. The periodic motions of such a machine tool system are determined through the mapping structures, and the stability and bifurcation conditions of the period-1 motions are determined by eigenvalue analysis. The variation of period-1 motions with respect to active excitation from a servo unit is presented from the bifurcation diagram of periodic nodes. Numerical simulations are carried out for small-amplitude and large-amplitude machine-tool vibration. The machine tool chatter occurs once the horizontal and vertical displacement of the machine-tool are out-of-phase. Such a relation could be used for the chatter detection of vibration-assisted machining.

Tài liệu tham khảo

Tobias SA (1965) Machine-tool Vibration. (trans: Burton AH). New York: John Wiley & Sons Brehl DE, Dow TA (2008) Review of vibration-assisted machining. Precis Eng 32:153–172 Zhang SJ, To S, Zhang GQ, Zhu ZW (2015) A review of machine-tool vibration and its influence upon surface generation in ultra-precision machining. Int J Mach Tool Manuf 91:34–42 Arnold RN (1946) Mechanism of tool vibration in cutting of steel. In: Proceedings Institution of Mechanical Engineers 154: 261-284 Tobias SA, Fishwick W (1958) Theory of regenerative machine tool chatter. Engineer 205(7):199–203 Tlusty J, Polacek M (1963) The stability of machine tools against self-excited vibration in machining. In: Processing of the ASME International Research in Production Engineering, Pittsburgh, PA: 465-474 Koenigsberger F, Tlusty J (1970) Machine tool structures, vol 1. Pergamon Press, New York Hooke JC, Tobias SA (1964) Finite amplitude instability – a new type of chatter. In: Proceeding of 4th MTDR: 97–100 Wiercigroch M, Budak E (2001) Sources of nonlinearities, chatter generation and suppression in metal cutting. Philos Trans R Soc A 359(1781):663–693 Hanna NH, Tobias SA (1974) A theory of nonlinear regenerative chatter. J Eng Ind 96(1):247–255 Tlusty J, Ismail F (1982) Basic nonlinearity in machining chatter. CIRP Ann 30:229–304 Shi HM, Tobias SA (1984) Theory of finite amplitude machine tool instability. Int J Mach Tool Des Res 24(1):45–69 Garbec I (1986) Chaos generated by the cutting process. Phys Lett A 117:394–386 Garbec I (1988) Chaotic dynamics of the cutting process. Int J Mach Tools Manuf 28:19–32 Moon FC, Kalmar-Nagy T (2001) Nonlinear models for complex dynamics in cutting materials. Philos Trans R Soc A 359:695–711 Insperger T, Stephan G, Turi J (2006) State-dependent delay in regenerative turning processes. Nonlinear Dyn 47:275–283 Gegg BC, Suh CS, Luo ACJ (2011) Machine tool vibration and cutting dynamics. Springer, New York Lehotzky D, Insperger T, Stepan G (2015) State-dependent, non-smooth model of chatter vibrations in turning. In: Proceedings of the ASME 2015 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference, Boston, Massachusetts, USA Liu MK, Suh CS (2012) On controlling milling instability and chatter at high speed. J Appl Nonlinear Dyn 1(1):59–72 Liu MK, Suh CS (2014) Simultaneous time-frequency control of friction induced instability. J Appl Nonlinear Dyn 3(3):227–244 Halfmann EC, Suh CS, Hung WNP (2017) Dynamics of turning operation Part I: experimental analysis using instantaneous frequency. J Vib Test Syst Dyn 1:15–33 Halfmann EC, Suh CS, Hung WNP (2017) Dynamics of turning operation Part II: model validation and stability at high speed. J Vib Test Syst Dyn 1:35–52 Halfmann EC, Suh CS (2017) On the temporal and spectral characteristics of micro-milling dynamics. J Vib Test Syst Dyn 1:177–193 Dassanayake AV, Suh CS (2017) Impact of tool geometry and tool feed on machining stability. J Vib Test Syst Dyn 1:295–317 Luo ACJ (2015) Discretization and implicit mapping dynamics. HEP/Springer, Beijing/Dordrecht Luo ACJ, Guo Y (2015) A semi-analytical prediction of periodic motions in Duffing oscillator through mapping structures. Discontin Nonlinearity Complex 4(2):121–150 Xing SY, Luo ACJ (2019) On a global sequential scenario of bifurcation trees to chaos in a first-order, periodically excited, time-delayed system. Int J Bifurc Chaos 29(10):1950141 Xing SY, Luo ACJ (2017) Towards infinite bifurcation trees of period-1 motions to chaos in a time-delayed, twin-well Duffing oscillator. J Vib Test Syst Dyn 1(4):353–392 Xu YY, Chen ZB, Luo ACJ (2019) On bifurcation trees of period-1 to period-2 motions in a nonlinear Jeffcott rotor system. Int J Mech Sci 160:429–450 Luo ACJ, Guo C (2019) A period-1 motion to chaos in a periodically forced, damped, double-pendulum. J Vib Test Syst Dyn 3(3):259–280 Guo Y, Luo ACJ (2017) Complete bifurcation trees of a parametrically driven pendulum. J Vib Test Syst Dyn 1(2):93–134