Robust stability of milling operations based on pseudospectral approach
The prediction of chatter-free machining parameters is not reliable for industrial applications without guaranteed robustness against modeling uncertainties. Measurement inaccuracies, fitting uncertainties, simplifications and modeling errors typically lead to a mismatch between the mathematical mod...
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Published in: | International journal of machine tools & manufacture Vol. 149; p. 103516 |
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Abstract | The prediction of chatter-free machining parameters is not reliable for industrial applications without guaranteed robustness against modeling uncertainties. Measurement inaccuracies, fitting uncertainties, simplifications and modeling errors typically lead to a mismatch between the mathematical model and the real physical system. This paper presents the robust stability analysis of milling operations based on a pseudospectral approach to take into account the effect of bounded parametric uncertainties both in the cutting coefficients and in the modal parameters. In order to make the predictions more accurate, the operational modal analysis of the spindle during rotation was conducted. The natural frequencies and damping ratios of the dominant vibration modes were identified from the impact tests of the rotating tool at different spindle speeds. The uncertainties of the fitted parameters were included in the computation of the pseudospectral radius of the monodromy operator of the time-periodic system. The solver is tested in a case study and experimental chatter tests are also included for demonstration purposes.
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•A robust pseudospectral method is presented for milling operations considering uncertainties in both modal parameters and cutting coefficients.•The stability analysis is based on a collocation method using Chebyshev polynomials.•Modal parameters of the rotating spindle are determined by operational modal analysis.•A case study with experimental chatter tests is included. |
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AbstractList | The prediction of chatter-free machining parameters is not reliable for industrial applications without guaranteed robustness against modeling uncertainties. Measurement inaccuracies, fitting uncertainties, simplifications and modeling errors typically lead to a mismatch between the mathematical model and the real physical system. This paper presents the robust stability analysis of milling operations based on a pseudospectral approach to take into account the effect of bounded parametric uncertainties both in the cutting coefficients and in the modal parameters. In order to make the predictions more accurate, the operational modal analysis of the spindle during rotation was conducted. The natural frequencies and damping ratios of the dominant vibration modes were identified from the impact tests of the rotating tool at different spindle speeds. The uncertainties of the fitted parameters were included in the computation of the pseudospectral radius of the monodromy operator of the time-periodic system. The solver is tested in a case study and experimental chatter tests are also included for demonstration purposes.
[Display omitted]
•A robust pseudospectral method is presented for milling operations considering uncertainties in both modal parameters and cutting coefficients.•The stability analysis is based on a collocation method using Chebyshev polynomials.•Modal parameters of the rotating spindle are determined by operational modal analysis.•A case study with experimental chatter tests is included. |
ArticleNumber | 103516 |
Author | Hajdu, David Michiels, Wim Borgioli, Francesco Insperger, Tamas Stepan, Gabor |
Author_xml | – sequence: 1 givenname: David surname: Hajdu fullname: Hajdu, David email: hajdu@mm.bme.hu organization: Department of Applied Mechanics, Budapest University of Technology and Economics, H-1111 Budapest, Hungary – sequence: 2 givenname: Francesco surname: Borgioli fullname: Borgioli, Francesco organization: Department of Computer Science, KU Leuven, Celestijnenlaan 200A, Leuven 3001, Belgium – sequence: 3 givenname: Wim surname: Michiels fullname: Michiels, Wim organization: Department of Computer Science, KU Leuven, Celestijnenlaan 200A, Leuven 3001, Belgium – sequence: 4 givenname: Tamas surname: Insperger fullname: Insperger, Tamas organization: Department of Applied Mechanics, Budapest University of Technology and Economics, H-1111 Budapest, Hungary – sequence: 5 givenname: Gabor surname: Stepan fullname: Stepan, Gabor organization: Department of Applied Mechanics, Budapest University of Technology and Economics, H-1111 Budapest, Hungary |
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Cites_doi | 10.1016/j.jsv.2013.09.043 10.1007/s40436-018-0230-0 10.1016/j.ijmachtools.2008.10.008 10.1016/j.ijmachtools.2014.09.014 10.1016/j.ijmachtools.2012.05.002 10.1007/s11071-016-3019-3 10.1115/1.3124088 10.1007/s00170-016-9044-z 10.23919/ECC.2018.8550382 10.1016/j.jsv.2007.11.006 10.1115/1.4007466 10.1016/j.jmapro.2017.09.015 10.1016/j.procir.2018.08.260 10.1137/120862399 10.1016/j.jmapro.2013.08.005 10.1007/s00170-016-8672-7 10.1016/j.ijmachtools.2011.02.002 10.1002/nme.3122 10.1016/j.ijmachtools.2019.01.002 10.3311/pp.me.2012-2.01 10.1007/s00170-016-8523-6 10.1115/1.2801317 10.1137/110856113 10.1016/j.cirp.2019.04.035 |
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Keywords | Uncertainty Robustness Collocation Pseudospectral method Chatter |
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SubjectTerms | Chatter Collocation Pseudospectral method Robustness Uncertainty |
Title | Robust stability of milling operations based on pseudospectral approach |
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