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Time-Domain Modeling of Torsional-Axial Chatter Vibrations in Indexable Drills with Low Damping
University West, Department of Engineering Science, Division of Manufacturing Processes. Sandvik Coromant, SE-811 81 Sandviken (SWE). (PTW)ORCID iD: 0000-0002-0390-9194
AB Sandvik Coromant, SE-811 81 Sandviken, Sweden..
University West, Department of Engineering Science, Division of Manufacturing Processes. University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. (PTW)ORCID iD: 0000-0003-0976-9820
University West, Department of Engineering Science, Division of Manufacturing Processes. (PTW)ORCID iD: 0000-0001-9331-7354
2015 (English)Conference paper, Published paper (Refereed)
Abstract [en]

In drills with helical chip flutes the coupling between axial and rotational degrees-of-freedom can cause chatter vibrations. These torsional-axial chatter vibrations can lead to a high frequency and unpleasant noise. It is desirable to design tools which are less prone to chatter vibrations and thus also makes less noise during operation. Dynamics of chatter vibrations in drilling is due to changes in chip-thickness that causes dynamic loads on the structure. These loads in return contribute and sustain vibrations. In this paper a simulation routine is proposed that can be used to model these chatter vibrations in drilling when damping of the drill-body is low. In case of low damping, the drill rotates backward in some instants. The importance of modeling of this phenomenon is emphasized in this paper and a method is proposed to model loads in case of backward rotations. The generated chip is calculated in each time-step and obtained chip-thickness is used to calculate dynamic loads. The structural responses are calculated in form of displacements by loading the drill with predicted dynamic loads based on the calculated chip thickness. Obtained displacements are used to calculate chip-thickness in the next time-step. Spectrum of simulated vibrations is compared with spectrum of measured noise and a good agreement between measurements and simulations is observed.

Place, publisher, year, edition, pages
Vancouver, 2015.
Keywords [en]
Drills, chatter vibrations, drilling, chatter vibration, torsional-axial coupling, low structural damping
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology; ENGINEERING, Manufacturing and materials engineering
Identifiers
URN: urn:nbn:se:hv:diva-8733OAI: oai:DiVA.org:hv-8733DiVA, id: diva2:875354
Conference
The 4th International Conference on Virtual Machining Process Technology (VMPT 2015)
Note

Ingår i avhandling.

The work was done in Sandvik Coromant in cooperation with University West in Sweden. Funding of the project provided by Sandvik Coromant and KK foundation is gratefully acknowledged. Moreover, all supports from The Research School of Simulation and Control of Material affecting Processes (SiCoMaP) are highly appreciated.

Available from: 2015-12-01 Created: 2015-12-01 Last updated: 2023-04-14Bibliographically approved
In thesis
1. Dynamics of Torsional and Axial Vibrations in Indexable Drills
Open this publication in new window or tab >>Dynamics of Torsional and Axial Vibrations in Indexable Drills
2015 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Drilling is widely used in manufacturing of products which need holes, for example for fluid channels, screws or pins. Depending on application, workpiece material, cutting parameters and economic considerations, different types of drills are employed. Indexable insert drills are types of drills which facilitate inserts to make holes. These types of drills can make high pitch noises due to vibrations. The focus of this thesis is to investigate the mechanism behind these vibrations in order to help reducing the generated noise in the future designs. Primary investigations show that the main mechanism which results the mentioned noise is regenerative chatter vibrations due to axial and torsional flexibilities. There is a gap in modeling of chatter vibrations in indexable drills where loadings and geometries are asymmetrical and due to torsional vibrations, delay terms are variable. The first step of simulating regenerative chatter vibrations in the drill is to model static cutting forces in a reliable way. In this thesis, a model is proposed which is capable of predicting static cutting forces through segmentation of cutting edges. Since, using this model, forces can be calculated separately on each insert, it is possible to consider differences of inserts in estimationof the cutting loads. The obtained loads are used in the chatter simulation.A model is proposed to simulate chatter vibrations by considering axialand angular deflections and the coupling between them. The resulted model isa system of delay differential equations with variable delays. Variations in timedelays, tool jump-outs and backward motions of inserts have been included inthe proposed time-domain simulation. A set of experiments is conducted toverify the model.

Place, publisher, year, edition, pages
Trollhättan: University West, 2015. p. 54
Series
Licentiate Thesis: University West ; 6
Keywords
Drilling Dynamics, Chatter Vibrations, Indexable Drills, Simulation
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology; ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-8736 (URN)978-91-87531-23-1 (ISBN)978-91-87531-22-4 (ISBN)
Presentation
(English)
Supervisors
Available from: 2015-12-01 Created: 2015-12-01 Last updated: 2019-12-03Bibliographically approved

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