Design of a simulation tool to identify stable milling processes

Duration:	May 1, 2005 - April 30, 2011
Project leaders:	D.Hömberg¹ and E.Uhlmann²
	¹Weierstrass Institute for Applied Analysis and Stochastics, Mohrenstrasse 39, 10117 Berlin
	Tel: +49 (0)30 - 20372 491 (office) / - 20372 555 (secretary)
	email: hoemberg@wias-berlin.de

	² University of Technology, Berlin, Strasse des 17. Juni 136, 10623 Berlin
	Tel: +49 (0)30 - 314 23349 (secretary)
	email: E. Uhlmann

Responsible:	O. Rott
	Weierstrass Institute for Applied Analysis and Stochastics, Mohrenstrasse 39, 10117 Berlin
	Tel: +49 (0)30 - 20372 584
	email:rott@wias-berlin.de

Cooperation:	Institut für Werkzeugmaschinen und Fabrikbetrieb (IWF), TU - Berlin
	IWF-project-summary.pdf

Support:	DFG SPP 1180 - Prediction and Manipulation of Interaction between Structure and Process

Introduction:

Chatter in milling is due to self-induced vibrations. The milling machine and the machined workpiece can be considered as a damped elastic structure, which is activated by a periodic cutting force. The feed per tooth, the spindle rotation speed and the axial depth of cut are the parameters to control the cutting process. A disadvantageous choice of these values often leads to unstable cutting conditions (chatter). Most of the current mathematical models, which are used to identify the parameter range of stable cutting, neglect the influence of the workpiece. Here an approach is developed which takes the elastic behavior of the workpiece into account.

Goals of the project:

development of a mathematical model for the coupled system (milling machine and workpiece)
simulation of workpiece temperature , workpiece vibration, machine vibration and material removal
movie: simulated system
numerical solution and stability analysis
optimization of machine design and process parameters
modeling of thermal effects
movie: simulated material removal and work piece vibrations

Recent Publications:

Rott, Oliver; Rasper, Patrick; Hömberg, Dietmar; Uhlmann, Eckart
Analysis of Uncertainties in the Stability Prediction for Milling Processes
Appeared in: Proceedings, 2nd International Conference on Process Machine Interactions, Vancouver, June 10-11, 2010, University of British Columbia, ISBN: 978-0-9866331-02
1470: Rott, Oliver; Jarlebring, Elias
An iterative method for the multipliers of periodic delay-differential equations and the analysis of a PDE milling model
Appeared in: Proceedings of the 9th IFAC Workshop on Time Delay Systems, Prague, June 7-9, 2010
Hömberg, Dietmar; Rott, Oliver
Modeling, analysis and stability of milling processes including workpiece effects
Appeared in: A.D. Fitt, J. Norbury, H. Ockendon, E. Wilson, eds., Progress in Industrial Mathematics at ECMI 2008, London, England, 30 June - 4 July 2008, ISBN: 978-3-642-12109-8
1361: Chełminski, Krzysztof; Hömberg, Dietmar; Rott, Oliver
On a thermomechanical milling model
1338: Rott, Oliver; Rasper, Patrick; Hömberg, Dietmar; Uhlmann, Eckart
A milling model with thermal effects including the dynamics of machine and work piece
Appeared in: B. Denkena, ed., Proceedings, 1st International Conference on Process Machine Interactions, Hannover, September 3-4, 2008, PZH Produktionstechnisches Zentrum GmbH, Garbsen, 2008, pp. 369--378
1151: Rott, Oliver; Hömberg, Dietmar; Mense, Carsten
A comparison of analytical cutting force models

last modified June 16, 2010