A Tool Tuning Approximation method: Exploration of the System Dynamics and its impact on Milling Stability when Amending Tool Stickout

TY - CONF

T1 - A Tool Tuning Approximation method

T2 - 24th International Conference on Material Forming

AU - Bertelsen, Nikolai

AU - Alphinas, Robert A.

AU - Ørskov, Klaus B.

N1 - Conference code: 24

PY - 2021/4/14

Y1 - 2021/4/14

N2 - The shortest possible tool stickout has been the traditional go-to approach with expectations of increased stability and productivity. However, experimental studies at Danish-Advanced-Manufacturing-Research-Center (DAMRC) have proven that for some tool stickout lengths, there exist local productivity optimums when utilizing the Stability Lobe Diagrams for chatter avoidance. This contradicts with traditional logic and the best practices taught to machinists. This paper explores the vibrational characteristics and behaviour of a milling system over the tool stickout length. The experimental investigation has been conducted by tap testing multiple endmills where the tool stickout length has been varied. For each length, the modal parameters have been recorded and mapped to visualize behavioural tendencies. The insights are conceptualized into a tool tuning approximation solution. It builds on an almost linear change in the natural frequencies when amending tool stickout, which results in changed positions of the Chatter-free Stability Lobes. Validation tests on the tool tuning approximation solution have shown varying success of the solution. This outlines the need for further research on the boundary conditions of the solution, to understand at which conditions the tool tuning approximation solution is applicable.

AB - The shortest possible tool stickout has been the traditional go-to approach with expectations of increased stability and productivity. However, experimental studies at Danish-Advanced-Manufacturing-Research-Center (DAMRC) have proven that for some tool stickout lengths, there exist local productivity optimums when utilizing the Stability Lobe Diagrams for chatter avoidance. This contradicts with traditional logic and the best practices taught to machinists. This paper explores the vibrational characteristics and behaviour of a milling system over the tool stickout length. The experimental investigation has been conducted by tap testing multiple endmills where the tool stickout length has been varied. For each length, the modal parameters have been recorded and mapped to visualize behavioural tendencies. The insights are conceptualized into a tool tuning approximation solution. It builds on an almost linear change in the natural frequencies when amending tool stickout, which results in changed positions of the Chatter-free Stability Lobes. Validation tests on the tool tuning approximation solution have shown varying success of the solution. This outlines the need for further research on the boundary conditions of the solution, to understand at which conditions the tool tuning approximation solution is applicable.

KW - Milling

KW - Modal parameters

KW - Stability lobes

KW - Tap testing

KW - Tool tuning

UR - http://www.scopus.com/inward/record.url?scp=85119381223&partnerID=8YFLogxK

U2 - 10.25518/esaform21.918

DO - 10.25518/esaform21.918

M3 - Paper

Y2 - 14 April 2021 through 16 April 2021

ER -