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Time Domain Simulation of Chatter Vibrations in Indexable Drills
University West, Department of Engineering Science, Division of Manufacturing Processes. (PTW)ORCID iD: 0000-0002-0390-9194
AB Sandvik Coromant, SE-811 81 Sandviken, Sweden..
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. (PTW)
University West, Department of Engineering Science, Division of Manufacturing Processes. (PTW)ORCID iD: 0000-0001-9331-7354
2017 (English)In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 89, no 1, 1209-1221 p.Article in journal (Refereed) Published
Abstract [en]

Regenerative chatter vibrations are common in drilling processes. These unwanted vibrations lead to considerable noise levels, damage the quality of the workpiece, and reduce tool life. The aim of this study is to simulate torsional and axial chatter vibrations as they play important roles in dynamic behavior of indexable insert drills with helical chip flutes. While asymmetric indexable drills are not the focal points in most of previous researches, this paper proposes a simulation routine which is adapted for indexable drills. Based on the theory of regenerative chatter vibration, a model is developed to include the asymmetric geometries and loadings that are inherent in the design of many indexable insert drills. Most indexable insert drills have two inserts located at different radial distances, namely central and peripheral inserts. Since the positions of the central and peripheral inserts are different, the displacement and thereby the change in chip thickness differs between the inserts. Additionally, the inserts have different geometries and cutting conditions, e.g., rake angle, coating, and cutting speed, which result in different cutting forces. This paper presents a time-domain simulation of torsional and axial vibrations by considering the differences in dynamics, cutting conditions, and cutting resistance for the central and peripheral inserts on the drill. The time-domain approach is chosen to be able to include nonlinearities in the model arising from the inserts jumping out of cut, multiple delays, backward motions of edges, and variable time delays in the system. The model is used to simulate cutting forces produced by each insert and responses of the system, in the form of displacements, to these forces. It is shown that displacements induced by dynamic torques are larger than those induced by dynamic axial forces. Finally, the vibration of a measurement point is simulated which is favorably comparable to the measurement results.

Place, publisher, year, edition, pages
London: Springer London, 2017. Vol. 89, no 1, 1209-1221 p.
Keyword [en]
Chatter, Indexable insert drill, Time-domain
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology; ENGINEERING, Manufacturing and materials engineering
Identifiers
URN: urn:nbn:se:hv:diva-8734DOI: 10.1007/s00170-016-9137-8ISI: 000394500300097OAI: oai:DiVA.org:hv-8734DiVA: diva2:875472
Note

Ingår i avhandling från 2015

Available from: 2015-12-01 Created: 2015-12-01 Last updated: 2017-04-19Bibliographically 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. 54 p.
Series
Licentiate Thesis: University West, 6
Keyword
Drilling Dynamics, Chatter Vibrations, Indexable Drills, Simulation
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
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: 2016-01-11Bibliographically approved

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