Dynamic modeling and chatter analysis of a spindle-workpiece-tailstock system for the turning of flexible parts

Kaibo Lu, Yongqian Wang, Fengshou Gu, Xinyu Pang, Andrew Ball

Research output: Contribution to journalArticle

Abstract

Chatter happens frequently in turning of flexible parts, jeopardizing the dynamic stability of the operation. The chatter stability prediction is dependent on the accurate estimation of the structural parameters of the cutting system. This paper aims to quantify the influence of the support conditions on dynamics of the flexible parts in straight turning. Given the time-varying cutting tool position during machining, first, the chatter stability of the cutting system along the cutting path is analyzed, and the critical stiffness expression for chatter onset prediction is deduced. Then, two models of the spindle-workpiece-tailstock system using analytical and numerical methods are constructed and compared. The simulation results showed that increasing the spindle bearing or tailstock support stiffness cannot effectively improve the stiffness distribution and the eigenfrequency of the machined rod, whereas the frequency of the system tends to be increased evidently with the chuck size decreased. In comparison with the experimental results, it has been shown that the model involving the effect of spindle bearing and center support enables to produce more accurate modal parameters estimation and chatter onset location prediction than the simplified model. Besides, the measured displacement signals demonstrate a good mapping relation with the theoretical analysis results. The present study could provide an in-depth understanding of the dynamic behavior of flexible workpieces in turning operations.
LanguageEnglish
Pages1-9
Number of pages9
JournalInternational Journal of Advanced Manufacturing Technology
Early online date7 Aug 2019
DOIs
Publication statusE-pub ahead of print - 7 Aug 2019

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Bearings (structural)
Stiffness
Chucks
Cutting tools
Parameter estimation
Numerical methods
Machining

Cite this

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title = "Dynamic modeling and chatter analysis of a spindle-workpiece-tailstock system for the turning of flexible parts",
abstract = "Chatter happens frequently in turning of flexible parts, jeopardizing the dynamic stability of the operation. The chatter stability prediction is dependent on the accurate estimation of the structural parameters of the cutting system. This paper aims to quantify the influence of the support conditions on dynamics of the flexible parts in straight turning. Given the time-varying cutting tool position during machining, first, the chatter stability of the cutting system along the cutting path is analyzed, and the critical stiffness expression for chatter onset prediction is deduced. Then, two models of the spindle-workpiece-tailstock system using analytical and numerical methods are constructed and compared. The simulation results showed that increasing the spindle bearing or tailstock support stiffness cannot effectively improve the stiffness distribution and the eigenfrequency of the machined rod, whereas the frequency of the system tends to be increased evidently with the chuck size decreased. In comparison with the experimental results, it has been shown that the model involving the effect of spindle bearing and center support enables to produce more accurate modal parameters estimation and chatter onset location prediction than the simplified model. Besides, the measured displacement signals demonstrate a good mapping relation with the theoretical analysis results. The present study could provide an in-depth understanding of the dynamic behavior of flexible workpieces in turning operations.",
keywords = "Modeling, Turning, Flexible workpieces, Spindle, Chuck, Chatter stability",
author = "Kaibo Lu and Yongqian Wang and Fengshou Gu and Xinyu Pang and Andrew Ball",
year = "2019",
month = "8",
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doi = "10.1007/s00170-019-04224-w",
language = "English",
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journal = "International Journal of Advanced Manufacturing Technology",
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T1 - Dynamic modeling and chatter analysis of a spindle-workpiece-tailstock system for the turning of flexible parts

AU - Lu, Kaibo

AU - Wang, Yongqian

AU - Gu, Fengshou

AU - Pang, Xinyu

AU - Ball, Andrew

PY - 2019/8/7

Y1 - 2019/8/7

N2 - Chatter happens frequently in turning of flexible parts, jeopardizing the dynamic stability of the operation. The chatter stability prediction is dependent on the accurate estimation of the structural parameters of the cutting system. This paper aims to quantify the influence of the support conditions on dynamics of the flexible parts in straight turning. Given the time-varying cutting tool position during machining, first, the chatter stability of the cutting system along the cutting path is analyzed, and the critical stiffness expression for chatter onset prediction is deduced. Then, two models of the spindle-workpiece-tailstock system using analytical and numerical methods are constructed and compared. The simulation results showed that increasing the spindle bearing or tailstock support stiffness cannot effectively improve the stiffness distribution and the eigenfrequency of the machined rod, whereas the frequency of the system tends to be increased evidently with the chuck size decreased. In comparison with the experimental results, it has been shown that the model involving the effect of spindle bearing and center support enables to produce more accurate modal parameters estimation and chatter onset location prediction than the simplified model. Besides, the measured displacement signals demonstrate a good mapping relation with the theoretical analysis results. The present study could provide an in-depth understanding of the dynamic behavior of flexible workpieces in turning operations.

AB - Chatter happens frequently in turning of flexible parts, jeopardizing the dynamic stability of the operation. The chatter stability prediction is dependent on the accurate estimation of the structural parameters of the cutting system. This paper aims to quantify the influence of the support conditions on dynamics of the flexible parts in straight turning. Given the time-varying cutting tool position during machining, first, the chatter stability of the cutting system along the cutting path is analyzed, and the critical stiffness expression for chatter onset prediction is deduced. Then, two models of the spindle-workpiece-tailstock system using analytical and numerical methods are constructed and compared. The simulation results showed that increasing the spindle bearing or tailstock support stiffness cannot effectively improve the stiffness distribution and the eigenfrequency of the machined rod, whereas the frequency of the system tends to be increased evidently with the chuck size decreased. In comparison with the experimental results, it has been shown that the model involving the effect of spindle bearing and center support enables to produce more accurate modal parameters estimation and chatter onset location prediction than the simplified model. Besides, the measured displacement signals demonstrate a good mapping relation with the theoretical analysis results. The present study could provide an in-depth understanding of the dynamic behavior of flexible workpieces in turning operations.

KW - Modeling

KW - Turning

KW - Flexible workpieces

KW - Spindle

KW - Chuck

KW - Chatter stability

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