Finite Element Prediction on the Machining Stability of Milling Machine with Experimental Verification
Chatter vibration has been a troublesome problem
for a machine tool toward the high precision and high speed machining.
Essentially, the machining performance is determined by the dynamic
characteristics of the machine tool structure and dynamics of cutting
process, which can further be identified in terms of the stability lobe
diagram. Therefore, realization on the machine tool dynamic behavior
can help to enhance the cutting stability. To assess the dynamic
characteristics and machining stability of a vertical milling system
under the influence of a linear guide, this study developed a finite
element model integrated the modeling of linear components with the
implementation of contact stiffness at the rolling interface. Both the
finite element simulations and experimental measurements reveal that
the linear guide with different preload greatly affects the vibration
behavior and milling stability of the vertical column spindle head
system, which also clearly indicate that the predictions of the
machining stability agree well with the cutting tests. It is believed that
the proposed model can be successfully applied to evaluate the
dynamics performance of machine tool systems of various
configurations.
[1] Yoshimi Ito, Modular design for machine tool, McGraw Hill Company,
2008.
[2] Y. Seo, D. P. Hong, I. Kim, T. Kim, D. Sheen, G. B. Lee, Structure
modeling of machine tools and internet-based implementation,
Proceedings of the 2005 Winter Simulation Conference, December 2005,
Orlando, Florida, USA.
[3] C. F. Beards, Damping in structural joints, The Shock and Vibration
Digest, 24(7) (1992) 3- 7.
[4] M. Yoshihara, Computer-aided design improvement of machine tool
states Incorporating joint dynamics data, Annals of the CIRP. 28(1) (1979)
241-246.
[5] Y.M. Huang, W.P. Fu, L.X. Dong, Research on the normal dynamic
characteristic parameters of joint surface, Journal of Mechanical
Engineering 29 (3) (1993) 74-77.
[6] Y. Lin, W. Chen, A method of identifying interface characteristic for
machine tools design, Journal of Sound and Vibration 255(3) (2002) 481-
487.
[7] G. P. Zhang , Y. M. Huang, W. H. Shi, W.P. Fu, Predicting dynamic
behaviors of a whole machine tool structure based on computer-aided
engineering, International Journal of Machine Tools & Manufacture, 43
(2003) 699-706.
[8] K. J. Johnson, Contact mechanics, Cambridge University Press (1985).
[9] H. Ohta, Sound of linear guideway type recirculating linear ball bearings,
Trans. ASME, Journal of Tribology. 121 (1999) 678-685.
[10] H. Ohta, E. Hayashi, Vibration of linear guideway type recirculating linear
ball bearings, Journal of Sound and Vibration. 235(5) (2000) 847-861.
[11] J. C. Chang, J. S. S. Wu, J. P. Hung, Characterization of the dynamic
behavior of a linear guideway mechanism, Structural Engineering
Mechanics. 25(1) (2007) 1-10.
[12] J. P. Hung, Load effect on the vibration characteristics of a stage with
rolling guides, Journal of Mechanical Science and Technology. 23(1)
(2009) 92-102.
[13] Hiwin Technologies Company. Hiwin linear guideway technical
information.Taiwan:HiwinCompany;2000. http://www.hiwin.com
[14] .Hiwin Technologies Company. Hiwin ballscrews technical information.
Taiwan: Hiwin Company; 2000. http://www.hiwin.com
[15] THK Technologies Company. THK Ball screw technical information: ball
screw peripheral. http://www.thk.com.
[16] THK CO., LTD., Features of the LM Guide, http://www.thk.com
[17] K. J. Johnson, Contact mechanics, Cambridge University Press (1985).
[18] D. E. Brewe, B. J. Hamrock, Simplified solution for elliptical-contact
deformation between two elastic solid, Trans. ASME, Journal of
Lubrication Technology. 99 (1997) 485-487.
[19] J. A. Greenwood, Analysis of elliptical Herztian contacts, Tribology
International. 30 (1997) 235-237.
[20] M. F. Zaeh, T. Oertli, Finite element modelling of ball screw feed drive
systems, Annals of the CIRP. 53(1) (2004) 289-293.
[21] C. Y. Lin, J. P. Hung, T. L. Lo, Effect of preload of linear guides on
dynamic characteristics of a vertical column-spindle system",
International Journal of Machine Tools and Manufacture. 5(8) (2010)
741-746.
[22] Y. Altintas, E. Budak, Analytical prediction of stability lobes in milling,
Annals of the CIRP. 44 (1) (1995) 357-362.
[23] Gagnol, B.C. Bouzgarrou, P. Ray, C. Barra, Model-based chatter stability
prediction for high-speed spindles. International Journal of Machine
Tools & Manufacture. 47 (2007) 1176-1186.
[24] E. Budak, Analytical models for high performance milling. Part I: Cutting
forces, structural deformations and tolerance integrity. International
Journal of Machine Tools & Manufacture. 46 (2006) 1478-1488.
[1] Yoshimi Ito, Modular design for machine tool, McGraw Hill Company,
2008.
[2] Y. Seo, D. P. Hong, I. Kim, T. Kim, D. Sheen, G. B. Lee, Structure
modeling of machine tools and internet-based implementation,
Proceedings of the 2005 Winter Simulation Conference, December 2005,
Orlando, Florida, USA.
[3] C. F. Beards, Damping in structural joints, The Shock and Vibration
Digest, 24(7) (1992) 3- 7.
[4] M. Yoshihara, Computer-aided design improvement of machine tool
states Incorporating joint dynamics data, Annals of the CIRP. 28(1) (1979)
241-246.
[5] Y.M. Huang, W.P. Fu, L.X. Dong, Research on the normal dynamic
characteristic parameters of joint surface, Journal of Mechanical
Engineering 29 (3) (1993) 74-77.
[6] Y. Lin, W. Chen, A method of identifying interface characteristic for
machine tools design, Journal of Sound and Vibration 255(3) (2002) 481-
487.
[7] G. P. Zhang , Y. M. Huang, W. H. Shi, W.P. Fu, Predicting dynamic
behaviors of a whole machine tool structure based on computer-aided
engineering, International Journal of Machine Tools & Manufacture, 43
(2003) 699-706.
[8] K. J. Johnson, Contact mechanics, Cambridge University Press (1985).
[9] H. Ohta, Sound of linear guideway type recirculating linear ball bearings,
Trans. ASME, Journal of Tribology. 121 (1999) 678-685.
[10] H. Ohta, E. Hayashi, Vibration of linear guideway type recirculating linear
ball bearings, Journal of Sound and Vibration. 235(5) (2000) 847-861.
[11] J. C. Chang, J. S. S. Wu, J. P. Hung, Characterization of the dynamic
behavior of a linear guideway mechanism, Structural Engineering
Mechanics. 25(1) (2007) 1-10.
[12] J. P. Hung, Load effect on the vibration characteristics of a stage with
rolling guides, Journal of Mechanical Science and Technology. 23(1)
(2009) 92-102.
[13] Hiwin Technologies Company. Hiwin linear guideway technical
information.Taiwan:HiwinCompany;2000. http://www.hiwin.com
[14] .Hiwin Technologies Company. Hiwin ballscrews technical information.
Taiwan: Hiwin Company; 2000. http://www.hiwin.com
[15] THK Technologies Company. THK Ball screw technical information: ball
screw peripheral. http://www.thk.com.
[16] THK CO., LTD., Features of the LM Guide, http://www.thk.com
[17] K. J. Johnson, Contact mechanics, Cambridge University Press (1985).
[18] D. E. Brewe, B. J. Hamrock, Simplified solution for elliptical-contact
deformation between two elastic solid, Trans. ASME, Journal of
Lubrication Technology. 99 (1997) 485-487.
[19] J. A. Greenwood, Analysis of elliptical Herztian contacts, Tribology
International. 30 (1997) 235-237.
[20] M. F. Zaeh, T. Oertli, Finite element modelling of ball screw feed drive
systems, Annals of the CIRP. 53(1) (2004) 289-293.
[21] C. Y. Lin, J. P. Hung, T. L. Lo, Effect of preload of linear guides on
dynamic characteristics of a vertical column-spindle system",
International Journal of Machine Tools and Manufacture. 5(8) (2010)
741-746.
[22] Y. Altintas, E. Budak, Analytical prediction of stability lobes in milling,
Annals of the CIRP. 44 (1) (1995) 357-362.
[23] Gagnol, B.C. Bouzgarrou, P. Ray, C. Barra, Model-based chatter stability
prediction for high-speed spindles. International Journal of Machine
Tools & Manufacture. 47 (2007) 1176-1186.
[24] E. Budak, Analytical models for high performance milling. Part I: Cutting
forces, structural deformations and tolerance integrity. International
Journal of Machine Tools & Manufacture. 46 (2006) 1478-1488.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:63695", author = "Jui P. Hung and Yuan L. Lai and Hui T. You", title = "Finite Element Prediction on the Machining Stability of Milling Machine with Experimental Verification", abstract = "Chatter vibration has been a troublesome problem
for a machine tool toward the high precision and high speed machining.
Essentially, the machining performance is determined by the dynamic
characteristics of the machine tool structure and dynamics of cutting
process, which can further be identified in terms of the stability lobe
diagram. Therefore, realization on the machine tool dynamic behavior
can help to enhance the cutting stability. To assess the dynamic
characteristics and machining stability of a vertical milling system
under the influence of a linear guide, this study developed a finite
element model integrated the modeling of linear components with the
implementation of contact stiffness at the rolling interface. Both the
finite element simulations and experimental measurements reveal that
the linear guide with different preload greatly affects the vibration
behavior and milling stability of the vertical column spindle head
system, which also clearly indicate that the predictions of the
machining stability agree well with the cutting tests. It is believed that
the proposed model can be successfully applied to evaluate the
dynamics performance of machine tool systems of various
configurations.", keywords = "Machining stability, Vertical milling machine, Linearguide, Contact stiffness.", volume = "4", number = "12", pages = "1469-7", }