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Suppression of regenerative chatter by the in process variation of rotational speed

Suppression of regenerative chatter by the in process variation of rotational speed

The aim of this research was to explore strategies based on the variation of the spindle rotation speed in order to eliminate self-excited regenerative vibrations, better known as chatter. This has led to the development of a method for regenerative chatter suppression based on strategies to vary the spindle speed during the process. These strategies deal with on the one hand continuous spindle speed variation (CSSV), and on the other automatic selection of a stable spindle speed. In order to reach this objective, a stability model has been developed that includes these strategies to be able to simulate its effectiveness.

Therefore, in order to analyse the stability of the milling process during machining at variable speed, a model has been developed that allows the inclusion of the strategy of continuous variation of the turning speed with different waveforms. A model of stability of the milling process in the time domain was developed, which allows the introduction of non-linear effects typical in the cutting process, as well as the simulation of tools with different geometries, mainly milling tools with inserts, one-piece helical tools, and spherical tip tools. Hence, the dynamic cutting forces and tool vibration can be obtained from the simulations. After the stability model was developed and validated, the strategy was compared with different variation forms.

However, the long computation time of the simulations makes it necessary to develop a semi-discretization model for the analysis of the stability of the system in a robust and fast way. For this reason, it is necessary that the model allows for different tool geometries as well as the orientation of the system modes.

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