An effective investigation of chatter prediction system on Al6061 alloy in an end milling process

• Published in: Journal of engineering and applied science (Online) Vol. 71; no. 1; pp. 150 - 17
• Main Authors: C, Trivikrama Raju, S, Jakeer Hussain, G, Yedukondalu, Kolli, Murahari
• Format: Journal Article
• Language: English
• Published: Berlin/Heidelberg Springer Berlin Heidelberg 01-12-2024; Springer Nature B.V; SpringerOpen
• Subjects: Al6061-alloy; Aluminum base alloys; Beam theory (structures); Chatter; Civil Engineering; Control algorithms; Controllers; Deformation effects; Design; Electrical Engineering; Engineering; Engineering Mathematics; Finite element method; Industrial Chemistry/Chemical Engineering; Investigations; Mechanical Engineering; Noise prediction; Optical microscope images; Optical microscopes; Production costs; Scanning electron microscope (SEM); Sensors; Shear deformation; Stability lobe diagrams; Stability lobes; Surface stability; Timoshenko beam theory; Timoshenko beams; Titanium alloys; Topography; Vibration; Stability lobe diagrams; Scanning electron microscope (SEM); Al6061-alloy; Timoshenko beam theory; Optical microscope images; Chatter
• ISSN: 1110-1903; 2536-9512
• DOI: 10.1186/s44147-024-00489-5

Visual examination of the surface topography, in conjunction with the other sensors, may confirm the existence of chatter. Online chatter detection during real machining operations is possible with the use of sensors, and the presence of noise in their output and restricted bandwidth are the major drawbacks of these sensors. Productivity drops and manufacturing costs go up when there is a lot of chatter in the machining process. In the present paper, an integrated spindle tool system is modeled using finite element method with Timoshenko beam theory including rotational and shear deformation effects. To maximize the average stable depth of cut in an end milling process while simultaneously minimizing the chatter vibration levels, real time and offline strategies have been investigated. Machining experiments performed on Al6061-alloy specimens provide an empirical confirmation of the stability boundaries. The surface topography methods such as scanning electron microscope (SEM) and optical microscope images along with vibration levels are considered, to identify chatter marks under various machining conditions, which helps to assure cutting process stability. Stability lobe diagrams are plotted with these derived conditions and observed at an incremental level in the axial depths of the cut. The methodology shown in this paper improves the machining stability of the end milling with the reduction in the tool tip vibrations.