Turn-milling machines are widely used in industry because of their multifunctional capabilities in producing complex parts in one setup. Both milling cutter and workpiece rotate simultaneously while the machine travels in three Cartesian directions leading to five axis kinematics with complex chip generation mechanism. This paper presents a general mathematical model to predict the chip thickness, cutting force, and chatter stability of turn milling operations. The dynamic chip thickness is modeled by considering the rigid body motion, relative vibrations between the tool and workpiece, and cutter-workpiece engagement geometry. The dynamics of the process are governed by delayed differential equations by time periodic coefficients with a time varying delay contributed by two simultaneously rotating spindles and kinematics of the machine. The stability of the system has been solved in semidiscrete time domain as a function of depth of cut, feed, tool spindle speed, and workpiece speed. The stability model has been experimentally verified in turn milling of Aluminum alloy cut with a helical cylindrical end mill.
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October 2018
Research-Article
Dynamics and Stability of Turn-Milling Operations With Varying Time Delay in Discrete Time Domain
Alptunc Comak,
Alptunc Comak
Manufacturing Automation Laboratory (MAL),
Department of Mechanical Engineering,
The University of British Columbia,
2054-6250 Applied Science Lane,
Vancouver, BC V6T 1Z4, Canada
e-mail: alptunc@alumni.ubc.ca
Department of Mechanical Engineering,
The University of British Columbia,
2054-6250 Applied Science Lane,
Vancouver, BC V6T 1Z4, Canada
e-mail: alptunc@alumni.ubc.ca
Search for other works by this author on:
Yusuf Altintas
Yusuf Altintas
Fellow ASME
Professor
Manufacturing Automation Laboratory (MAL),
Department of Mechanical Engineering,
The University of British Columbia,
Vancouver, BC V6T 1Z4, Canada
e-mail: altintas@mech.ubc.ca
Professor
Manufacturing Automation Laboratory (MAL),
Department of Mechanical Engineering,
The University of British Columbia,
2054-6250 Applied Science Lane
,Vancouver, BC V6T 1Z4, Canada
e-mail: altintas@mech.ubc.ca
Search for other works by this author on:
Alptunc Comak
Manufacturing Automation Laboratory (MAL),
Department of Mechanical Engineering,
The University of British Columbia,
2054-6250 Applied Science Lane,
Vancouver, BC V6T 1Z4, Canada
e-mail: alptunc@alumni.ubc.ca
Department of Mechanical Engineering,
The University of British Columbia,
2054-6250 Applied Science Lane,
Vancouver, BC V6T 1Z4, Canada
e-mail: alptunc@alumni.ubc.ca
Yusuf Altintas
Fellow ASME
Professor
Manufacturing Automation Laboratory (MAL),
Department of Mechanical Engineering,
The University of British Columbia,
Vancouver, BC V6T 1Z4, Canada
e-mail: altintas@mech.ubc.ca
Professor
Manufacturing Automation Laboratory (MAL),
Department of Mechanical Engineering,
The University of British Columbia,
2054-6250 Applied Science Lane
,Vancouver, BC V6T 1Z4, Canada
e-mail: altintas@mech.ubc.ca
1Corresponding author.
Manuscript received November 28, 2017; final manuscript received June 21, 2018; published online July 27, 2018. Assoc. Editor: Satish Bukkapatnam.
J. Manuf. Sci. Eng. Oct 2018, 140(10): 101013 (14 pages)
Published Online: July 27, 2018
Article history
Received:
November 28, 2017
Revised:
June 21, 2018
Citation
Comak, A., and Altintas, Y. (July 27, 2018). "Dynamics and Stability of Turn-Milling Operations With Varying Time Delay in Discrete Time Domain." ASME. J. Manuf. Sci. Eng. October 2018; 140(10): 101013. https://doi.org/10.1115/1.4040726
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