Modeling And Simulation Of Chatter Stability On Milling Process Considering The Effect Of Torsional Vibration

Chatter is a self-exicited vibration occured during cutting process,resulting from the inherent characteristics of the machining system without the effect of periodic external force.It will seriously limit the quality and efficiency of the cutting process.When the rigidity in the torsional direction is weak,the chatter not only occurs in the transverse direction,but also occurs in the torsional direciton,which may results obvious vibration marks occurs in circular corner of the machined part.Therefore,it is very important to establish the dynamic model of the milling process considering the effect of torsional vibraiton,and thus to achieve the high-efficiency chatter-free cutting.The paper will focus on the modeling and simulation for the milling process considering the effect of torsional vibration theoretically and experimentally,and its main contents are as follows:First of all,the dynamic modeling of the cutting process for the conventional 2-DOF milling system and its analytical solution and semi-discretization solution methods were introduced in detail.On the basis,the stability prediction of the conventional 2-DOF milling system was implemented using programming method,which lays foundation for further research.Secondly,the modal analysis is conducted for the cutting tool using the finite element analysis method,and the natural frequencies and the mode shapes of the machine–tool system is obtained.On the basis,the dynamic model of milling system is deduced by simplifying the milling system as 3-DOF vibration system(two lateral vibrations and one torsional vibration),an improved semi–discretization method is used to solve the dynamic model,and as a result the chatter stability can be predicted.Based on the results of dynamic modeling,the prediction of chatter stability of milling process considering the effect of torsional vibration is implemented on Matlab platform using GUI.With the aid of the developed dynamic simulation system,the effect of modal parameters on milling stability is analyzed,and some conclusions are drawn which may be useful to practical engineering applications.Lastly,the verification tests for chatter stability are performed,and the correctness of the established model and the corresponding simulation program are verified.