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Controlling Chatter Vibrations During Milling of a Flexible Part

 

Abstract: One of the most important problems during machining a flexible part such as turbine and compressor blades is self-exited chatter vibration. This vibration reduces metal removal rate "MRR", deteriorates surface roughness of the part and causes breakage of tool or part. In conventional method the optimized cutting condition is determined by trial and error with losing­ several tools or parts. In this research milling operation of a flexible part is simulated using a developed comprehensive model comprising of the following modules: 1. Dynamic-regenerative model of milling process 2. Finite Element Model of tool-spindle and work piece. For large woc (radial width of cut) chatter vibration can be controlled by means of doc (ay.ial depth of cut) vs. spindle-speed stability lobes. But, for small woc, slight increase in woc dramatically increase in-cut segment of the cutting tool, therefore it has the main role in exiting chatter vibration which can be controlled by means of woc vs. spindle-speed stability lobes. Prior to any machining operation, the comprehensive model anticipates the optimum cutting conditions and simulates the vibrations and surface roughness.

 Keywords: Milling Simulation, Flexible Part Machining, Surface Finish ­

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