Technical Brief

Optimal Detuning of a Parallel Turning System—Theory and Experiments

[+] Author and Article Information
Marta J. Reith

Department of Applied Mechanics,
Budapest University of Technology and Economics,
Budapest 1111, Hungary
e-mail: reith@mm.bme.hu

Daniel Bachrathy

Assistant Professor Department of Applied Mechanics,
Budapest University of Technology and Economics,
Budapest 1111, Hungary
e-mail: bachrathy@mm.bme.hu

Gabor Stepan

Department of Applied Mechanics,
Budapest University of Technology and Economics,
Budapest 1111, Hungary
e-mail: stepan@mm.bme.hu

Contributed by the Dynamic Systems Division of ASME for publication in the JOURNAL OF DYNAMIC SYSTEMS, MEASUREMENT, AND CONTROL. Manuscript received October 16, 2015; final manuscript received August 8, 2016; published online October 17, 2016. Assoc. Editor: Jingang Yi.

J. Dyn. Sys., Meas., Control 139(1), 014503 (Oct 17, 2016) (7 pages) Paper No: DS-15-1515; doi: 10.1115/1.4034497 History: Received October 16, 2015; Revised August 08, 2016

Parallel turning is an excellent candidate for keeping up with current trends set by manufacturing industry, namely, to increase accuracy and productivity simultaneously. In the field of manufacturing of cylindrical parts, these cutting processes offer huge potential in increasing productivity, since they ensure high material removal rates and appropriate accuracy at the same time. The above benefits can yet only be harvested if the process is free of chatter vibration, which affects the workpiece surface quality. In this study, it is shown that by means of tuning the dynamical properties of cutting tools, it is possible to expand the stable machining parameter regions in order to eliminate adverse chatter. A parallel turning system is investigated, where tuning of the system is realized by varying the overhang of one of the tools, that is, by modulating the frequency ratio of the cutters. Measurements have been carried out for the validation of the theoretical predictions of robustly stable chip width limits, below which the turning operation is stable for all spindle speed values.

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Fig. 1

Setup for the investigated two-cutter turning process

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Fig. 2

Mechanical model of two-cutter turning system

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Fig. 3

Stability lobes (thin lines) and enveloping limits (horizontal thick lines) of the two-cutter turning model

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Fig. 4

(a) wRS over ΔL, (b) wRS over Δm, and (c) wRS over f1/f2 for additional overhang (light line) and additional mass (dark lines)

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Fig. 5

Modal parameter functions fitted for different L1 tool overhang values: (a) modal mass, (b) modal stiffness, (c) natural frequency, and (d) damping ratio

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Fig. 6

Predicted robust chip width limits for different modal parameters (light—theoretical, dark—fitted trends, and dark with diamonds—actually measured) as a function of tool frequency ratios and measured stable (circle) and unstable (cross) machining points




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