@article{MTMT:34539200, title = {Chatter detection and suppression in machining processes: a comprehensive analysis}, url = {https://m2.mtmt.hu/api/publication/34539200}, author = {Basit, Abdul and Khan, Niaz Bahadur and Ali, Sadaqat and Muhammad, Riaz and Abduvalieva, Dilsora and Khan, M. Ijaz and Jameel, Mohammed}, doi = {10.1007/s12008-023-01716-8}, journal-iso = {IJIDEM}, journal = {INTERNATIONAL JOURNAL ON INTERACTIVE DESIGN AND MANUFACTURING}, volume = {Előzetes kiadás / Early view}, unique-id = {34539200}, issn = {1955-2513}, year = {2024}, eissn = {1955-2505} } @article{MTMT:34539203, title = {Diametral error correction in turning slender workpieces: an integrated approach}, url = {https://m2.mtmt.hu/api/publication/34539203}, author = {Grossi, Niccolo and Scippa, Antonio and Campatelli, Gianni}, doi = {10.1007/s00170-023-12825-9}, journal-iso = {INT J ADV MANUFACT TECHNOL}, journal = {INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY}, volume = {130}, unique-id = {34539203}, issn = {0268-3768}, year = {2024}, eissn = {1433-3015}, pages = {1393-1404} } @article{MTMT:34539199, title = {Chatter Avoidance by Spindle Speed and Orientation Planning in Five-Axis Ball-End Milling of Thin-Walled Blades}, url = {https://m2.mtmt.hu/api/publication/34539199}, author = {Karimi, Behnam and Altintas, Yusuf}, doi = {10.1115/1.4063654}, journal-iso = {J MANUF SCI E-T ASME}, journal = {JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME}, volume = {146}, unique-id = {34539199}, issn = {1087-1357}, year = {2024}, eissn = {1528-8935}, pages = {021006} } @article{MTMT:34297925, title = {Advanced adaptive feed control for CNC machining}, url = {https://m2.mtmt.hu/api/publication/34297925}, author = {Kim, S. G. and Heo, E. Y. and Lee, H. G. and Kim, D. W. and Yoo, N. H. and Kim, T. H.}, doi = {10.1016/j.rcim.2023.102621}, journal-iso = {ROBOT CIM-INT MANUF}, journal = {ROBOTICS AND COMPUTER-INTEGRATED MANUFACTURING}, volume = {85}, unique-id = {34297925}, issn = {0736-5845}, abstract = {In computer numerical control (CNC) machining, the tool feed rate is crucial for determining the machining time. It also affects the degree of tool wear and the final product quality. In a mass production line, the feed rate guides the production cycle. On the other hand, in single-time machining, such as for molds and dies, the tool wear and product quality are influenced by the length of machining time. Accordingly, optimizing the CNC program in terms of the feed rate is critical and should account for various factors, such as the cutting depth, width, spindle speed, and cutting oil. Determining the optimal tool feed rate, however, can be challenging given the various machine tools, machining paths, and cutting conditions involved. It is important to balance the machining load by equalizing the tool's load, reducing the machining time during no-load segments, and controlling the feed rate during high load segments. In this study, an advanced adaptive control method was designed that adjusts the tool feed rate in real time during rough machining. By predicting both the current and future machining load based on the tool position and time stamp, the proposed method combines reference load control curves and cutting characteristics, unlike existing passive adaptive control methods. Four different feed control methods were tested including conventional and proposed adaptive feed control. The results of the comparative analysis was presented with respect to the average machining load and tool wear, the machining time, and the average tool feed speed. When the proposed adaptive control method was used, the production time was reduced up to 12.8% in the test machining while the tool life was increased.}, keywords = {Computer numerical control (CNC) machining; Tool feed rate; Cutting load; Reference load control curve (RLCC); Advanced adaptive feed control}, year = {2024}, eissn = {1879-2537} } @article{MTMT:34539205, title = {Online chatter detection for single-point diamond turning based on multidimensional cutting force fusion}, url = {https://m2.mtmt.hu/api/publication/34539205}, author = {Li, Denghui and Du, Hanheng and Yip, Wai Sze and Tang, Yuk Ming and To, Suet}, doi = {10.1016/j.ymssp.2023.110850}, journal-iso = {MECH SYST SIGNAL PR}, journal = {MECHANICAL SYSTEMS AND SIGNAL PROCESSING}, volume = {206}, unique-id = {34539205}, issn = {0888-3270}, year = {2024}, eissn = {1096-1216}, pages = {110850} } @article{MTMT:34585494, title = {Stability Analysis in Milling Based on the Localized Differential Quadrature Method}, url = {https://m2.mtmt.hu/api/publication/34585494}, author = {Mei, Yonggang and He, Bingbing and He, Shangwen and Ren, Xin}, doi = {10.3390/mi15010054}, journal-iso = {MICROMACHINES-BASEL}, journal = {MICROMACHINES}, volume = {15}, unique-id = {34585494}, abstract = {Chatter stability analysis is an effective way to optimize the cutting parameters and achieve chatter-free machining. This paper proposes a milling chatter stability analysis method based on the localized differential quadrature method (LDQM), which has the advantages of simple principle, easy application, and high computational efficiency. The milling process, considering the regeneration effect, is modeled using linear periodic delay differential equations (DDE), then the state transition matrix during the adjacent cutting period is constructed based on the LDQM, and finally, the stability of the milling process is obtained based on the Floquet theory. The accuracy and computation efficiency of the proposed method are verified through two benchmark milling models. The simulation results demonstrate that the proposed method in this paper can accurately and quickly obtain the chatter stability lobe diagram (SLD) of the milling process, which will provide guidance for optimizing the process parameters.}, keywords = {STABILITY ANALYSIS; Formulation; CHATTER; Semi-discretization method; Milling; Chemistry, Analytical; Nanoscience & Nanotechnology; Instruments & Instrumentation; Chatter suppression; ANALYTICAL PREDICTION; localized differential quadrature method}, year = {2024}, eissn = {2072-666X} } @article{MTMT:34539202, title = {Enhancing tool dynamics and stability in internal turning with an adjustable clamping device under variable cutting conditions}, url = {https://m2.mtmt.hu/api/publication/34539202}, author = {Yan, Shuyang and Sun, Yuwen}, doi = {10.1016/j.ymssp.2023.111007}, journal-iso = {MECH SYST SIGNAL PR}, journal = {MECHANICAL SYSTEMS AND SIGNAL PROCESSING}, volume = {208}, unique-id = {34539202}, issn = {0888-3270}, year = {2024}, eissn = {1096-1216}, pages = {111007} } @article{MTMT:33848890, title = {Identification of in-process machine tool dynamics using forced vibrations in milling process}, url = {https://m2.mtmt.hu/api/publication/33848890}, author = {Akbari, Vahid Ostad Ali and Mohammadi, Yaser and Kuffa, Michal and Wegener, Konrad}, doi = {10.1016/j.ijmecsci.2022.107887}, journal-iso = {INT J MECH SCI}, journal = {INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES}, volume = {239}, unique-id = {33848890}, issn = {0020-7403}, abstract = {An accurate description of machine tool dynamics is essential for health monitoring, chatter prevention, and improvement of manufacturing accuracy. The standard identification approach of experimental modal analysis at the standstill of the machine does not realize the possible variations in the dynamics due to operational conditions. The in-process identification methods in the literature, on the other hand, are associated with implementation difficulties in industrial environments due to the required complex and specially-designed setup, limited excitation forms, or excessive measurement efforts. This paper proposes an industrial-friendly method to estimate the in-process structural dynamics of machine tools, considering practical demands and implementation limits. Knowing that the operational dependency of the dynamics is associated with the machine and spindle structure, the machine-spindle and holder-tool structures are considered two distinguished subsystems. The cross Frequency Response Function (FRF) of the coupled structure, between the tooltip and spindle flange, is determined by measuring forced vibrations during milling operations. The milling forces are considered as excitation input and the process is designed to be stable and chatter-free so that the simulated forces can be accurately used in the identification. Then, the receptance coupling theory is utilized to develop an optimization algorithm. Given the model of the coupled structure, the evolutionary optimization tunes the modal parameters of the machine-spindle dynamics and joint parameters until the predicted cross FRFs match the experimentally determined FRFs. The direct FRF at the tooltip is predicted using identified in-process machine-spindle dynamics through the receptance coupling method. The identified in-process dynamics are used to predict stability diagrams for different tooling systems and, moreover, to design an augmented Kalman filter to estimate cutting forces. Comparison of estimated SLDs and cutting forces with chatter test results and dynamometer measurements validate the outcomes of the proposed identification method. This paper demonstrates that the system dynamics under operational conditions can be successfully identified without requiring costly setup, specially-designed workpieces or operations, and destructive chatter tests.}, keywords = {CHATTER STABILITY; Receptance coupling substructure analysis; machine tool dynamics; In-process dynamics}, year = {2023}, eissn = {1879-2162}, orcid-numbers = {Mohammadi, Yaser/0000-0001-7798-4616} } @article{MTMT:34297927, title = {Reluctance-Based Modular Active Damper for Chatter Suppression in Boring Bars With Different Overhangs}, url = {https://m2.mtmt.hu/api/publication/34297927}, author = {Astarloa, Asier and Wahab, Fagher and Mancisidor, Iker and Fernandes, Maria Helena and Etxaniz, Inigo and Munoa, Jokin}, doi = {10.1109/TMECH.2023.3295170}, journal-iso = {IEEE-ASME T MECH}, journal = {IEEE-ASME TRANSACTIONS ON MECHATRONICS}, unique-id = {34297927}, issn = {1083-4435}, abstract = {Boring operations are usually limited by chatter vibrations related to the flexibility of boring bars. The location of a passive tuned mass damper close to the tool tip is a widely proposed solution, which has demonstrated robust results. However, the main drawback of this solution is that the dampers must be tuned for a certain frequency, being a customized solution for each boring bar. Active devices can overcome this limitation due to their adaptability to changing actuation frequencies. This work describes the development of a reluctance-based modular active inertial damper for its application in the suppression of chatter vibrations in slender boring bars. The solution provides the possibility to perform chatter-free boring operations at different bar overhangs due to the important stability improvement obtained in a broad frequency range.}, keywords = {CHATTER; active damping; Boring}, year = {2023}, eissn = {1941-014X}, orcid-numbers = {Fernandes, Maria Helena/0000-0001-7293-7976} } @article{MTMT:33907260, title = {NUMERICAL EVALUATION OF PLANE GRINDING STABILITY}, url = {https://m2.mtmt.hu/api/publication/33907260}, author = {Barjasic, Danijel and Stegic, Milenko and Juran, Marin}, doi = {10.21278/TOF.471046522}, journal-iso = {T FAMENA}, journal = {TRANSACTIONS OF FAMENA}, volume = {47}, unique-id = {33907260}, issn = {1333-1124}, abstract = {Regenerative chatter is a serious productivity limitation in machining. The term refers to unstable relative vibrations between the workpiece and the cutting tool that negatively affect almost all cutting operations by chip removal. Grinding is the most commonly used abrasive process. As a result of significant tool wear in grinding, surface regeneration (which causes regenerative chatter) can occur on the workpiece and around the grinding wheel circumference. This study examines only the regenerative mechanism related to the grinding wheel, i.e., the effect of distributed grain dullness in particular, which causes instability in the machining processes. A chatter vibration model was formulated and validated by numerical simulations and experimental data. For the first time, the new model accurately predicts the existence of a region of stability in the grinding process. That new model refutes the previous model stating that grinding cannot be stable considering grinding wheel regeneration.}, keywords = {machine tool dynamics; Grinding chatter; Wheel regeneration}, year = {2023}, eissn = {1333-1124}, pages = {13-20} } @article{MTMT:33769724, title = {Stability Analysis of a One Degree of Freedom Robot Model with Sampled Digital Acceleration Feedback Controller in Turning and Milling}, url = {https://m2.mtmt.hu/api/publication/33769724}, author = {Bártfai, András and Barrios, Asier and Dombóvári, Zoltán}, doi = {10.1115/1.4062229}, journal-iso = {J COMPUT NONLIN DYN}, journal = {JOURNAL OF COMPUTATIONAL AND NONLINEAR DYNAMICS}, volume = {2022 IDETC-CIE Selected Papers from the MSNDC Conference}, unique-id = {33769724}, issn = {1555-1415}, abstract = {This study is interested in the stability of robots in machining. The goal is to improve the dynamic performance of robots using an additional acceleration signal fed back through the conventional built-in proportional-derivative controller provided by the manufacturer. The structure of the robot is modelled with a simple one degree of freedom lumped model and the control signals are fed back via a linear spring and damping. The time delays of feedback controllers are considered zero-order holds, which results in sawtooth-like time-periodic time delays. The resulting equation of motion is an advanced delay differential equation. The semidiscretization method is shown for such systems having multiple sampled digital delays and continuous delays. First, we establish the stable regions in the plane of the sampling delay and the gain of the acceleration signal without machining. Then we show the possibility to improve stability in turning and milling using the additional acceleration feedback controller compared to the cases without any controller or using only the built-in proportional-derivative controller.}, year = {2023}, eissn = {1555-1423}, pages = {1-9}, orcid-numbers = {Dombóvári, Zoltán/0000-0003-2591-3220} } @article{MTMT:34434611, title = {Hybrid vibration absorber for self-induced vibration suppression: exact analytical formulation for acceleration feedback control}, url = {https://m2.mtmt.hu/api/publication/34434611}, author = {Bartos, M. and Habib, Giuseppe}, doi = {10.1007/s11012-023-01731-9}, journal-iso = {MECCANICA}, journal = {MECCANICA}, volume = {58}, unique-id = {34434611}, issn = {0025-6455}, year = {2023}, eissn = {1572-9648}, pages = {2269-2289}, orcid-numbers = {Habib, Giuseppe/0000-0003-3323-6901} } @article{MTMT:32510579, title = {Effect of axial force on the stability of milling: Local bifurcations around stable islands}, url = {https://m2.mtmt.hu/api/publication/32510579}, author = {Béri, Bence and Stépán, Gábor}, doi = {10.1177/10775463211048256}, journal-iso = {J VIB CONTROL}, journal = {JOURNAL OF VIBRATION AND CONTROL}, volume = {29}, unique-id = {32510579}, issn = {1077-5463}, abstract = {In this paper, the stability properties of milling processes are presented when the axial component of the cutting force is also taken into account as a compressive force acting on the cutting tool. The mechanism of the material removal operation is described by a one degree-of-freedom oscillator subjected to the so-called surface regeneration effect. This can be represented mathematically by a nonlinear, time-periodic, delay differential equation. The regenerative compression affects the natural frequency of the system, which is modelled through the lateral stiffness variation of the bearing support of the main spindle. This extension of the general milling model leads to the birth of stable islands within the originally unstable parameter domain. Since the exploitation of these regions may open new ways in practice for increasing the efficiency of machining, the domain of attraction is investigated qualitatively near the stability boundaries of the stable island by means of a semi-analytical method.}, year = {2023}, eissn = {1741-2986}, pages = {440-452}, orcid-numbers = {Béri, Bence/0000-0002-3559-2865; Stépán, Gábor/0000-0003-0309-2409} } @article{MTMT:34171038, title = {Sensor and actuator integrated tooling systems}, url = {https://m2.mtmt.hu/api/publication/34171038}, author = {Bleicher, F. (2) and Biermann, D. (1) and Drossel, W.-G. (2) and Moehring, H.-C. (2) and Altintas, Y. (1)}, doi = {10.1016/j.cirp.2023.05.009}, journal-iso = {CIRP ANN-MANUF TECHN}, journal = {CIRP ANNALS-MANUFACTURING TECHNOLOGY}, volume = {72}, unique-id = {34171038}, issn = {0007-8506}, year = {2023}, eissn = {1726-0604}, pages = {673-696} } @article{MTMT:34297932, title = {Application of Geometric Simulation for Determination of Dynamic Undeformed Chip Thickness in Milling}, url = {https://m2.mtmt.hu/api/publication/34297932}, author = {Bombinski, Sebastian and Jemielniak, Krzysztof}, doi = {10.12913/22998624/157114}, journal-iso = {ADV SCI TECHNOL RES J}, journal = {ADVANCES IN SCIENCE AND TECHNOLOGY-RESEARCH JOURNAL}, volume = {17}, unique-id = {34297932}, issn = {2080-4075}, abstract = {Self-excited vibration is a significant constraint on productivity and production quality, which makes various forms of virtual machining widely used to find stable conditions before starting the actual machining operation. Numeri-cal simulation of self-excited vibration, although much slower than analytical solutions, makes it possible to con-sider the nonlinearity of the process and its continuous variation. In 5-axis milling, predicting the instantaneous cross-sections of the uncut chip is very difficult, so geometric simulation is readily used to check the correctness of the NC program and the obtained shape of the workpiece. However, the known solutions take into consideration only programmed movements of the tool relative to the workpiece without considering vibrations, and those in which attempts have been made to consider vibrations have significant limitations. This paper uses a Geometric Simulator that determines the nominal positions of the tool relative to the workpiece, to which the displacements due to vibration, determined by the Dynamic Simulator, are added, making it possible to effectively determine the dynamic thickness of the cut layer and the trace on the workpiece material left by the vibrating tool. The use of geometric simulation, in which the material is represented by discrete voxels, introduces signal quantization, that is, the limited resolution of undeformed chip thickness and trace left on the machined surface. The paper presents the effect of voxel dimension on the accuracy of the simulation of self-excited vibrations}, keywords = {computer graphics; Numerical simulation; self-excited vibration; 5-axis milling}, year = {2023}, eissn = {2299-8624}, pages = {173-181} } @article{MTMT:34539204, title = {Finite-frequency H∞ control for active chatter suppression in turning}, url = {https://m2.mtmt.hu/api/publication/34539204}, author = {Chen, Jie and Ma, Haifeng and Liu, Zhanqiang and Song, Qinghua and Xiong, Zhenhua}, doi = {10.1007/s00170-023-12593-6}, journal-iso = {INT J ADV MANUFACT TECHNOL}, journal = {INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY}, volume = {129}, unique-id = {34539204}, issn = {0268-3768}, year = {2023}, eissn = {1433-3015}, pages = {5075} } @article{MTMT:33837409, title = {Automatic feature extraction for online chatter monitoring under variable milling conditions}, url = {https://m2.mtmt.hu/api/publication/33837409}, author = {Chen, Kunhong and Zhang, Xing and Zhao, Wanhua}, doi = {10.1016/j.measurement.2023.112558}, journal-iso = {MEASUREMENT}, journal = {MEASUREMENT}, volume = {210}, unique-id = {33837409}, issn = {0263-2241}, abstract = {Chatter is an unpredictable self-excited vibration phenomenon in the milling process, which can seriously affect machining efficiency and quality. In the aerospace industry, the cutting process lasts for an extended period, and the cutting parameters continuously change. This paper presents an automated method for monitoring chatter in this field. Recurrence plot (RP) can accurately reflect dynamic changes in the cutting system, but its hyper-parameters must be set in advance. This paper initially proposes a novel adaptive particle swarm algorithm (APSO) for calculating hyperparameters so that RP can be obtained automatically. Then, as the global and local features of RP show clear changes in different cutting states, a deep neural network architecture that can extract features from multiple scales is developed. Three categories of experiments are conducted to test the proposed method. Experimental results show that the proposed method can achieve accurate online chatter monitoring under different cutting conditions.}, keywords = {RP; deep learning neural network; Automatic feature extraction; APSO; Online chatter monitoring}, year = {2023}, eissn = {1873-412X}, orcid-numbers = {Chen, Kunhong/0000-0002-2843-4439} } @article{MTMT:34242600, title = {Physics-guided high-value data sampling method for predicting milling stability with limited experimental data}, url = {https://m2.mtmt.hu/api/publication/34242600}, author = {Chen, Lu and Li, Yingguang and Chen, Gengxiang and Liu, Xu and Liu, Changqing}, doi = {10.1007/s10845-023-02190-5}, journal-iso = {J INTELL MANUF}, journal = {JOURNAL OF INTELLIGENT MANUFACTURING}, unique-id = {34242600}, issn = {0956-5515}, abstract = {Accurate milling stability prediction is necessary for selecting chatter-free machining parameters to ensure the machining quality. With the development of machine learning techniques, data-driven methods have demonstrated powerful modelling capabilities for stability prediction. However, the significant performance of data-driven modelling usually requires a large labelled training dataset consisting of stable and unstable experimental data, which is expensive and time-consuming for metal-cutting scenarios. Therefore, how to design an experimental parameter set to build the experimental labelled dataset which is small but can provide sufficient support for data-driven stability prediction has been a critical problem and has received increasing attention. Existing research samples the experimental parameters by the grid or the boundary method, which inevitably brings lots of low-value data points for model training. To address this, this paper proposes a Physics-Guided High-Value (PGHV) data sampling method to reduce the required experiments for data-driven stability prediction. A novel value function is designed based on the physics information of milling dynamic stability to quantify the potential contribution of different experimental parameters. The optimal experimental parameter set can then be determined by maximising the dataset value. After that, the experimental labelled dataset can be constructed by performing cutting experiments under the sampled experimental parameters. Finally, the stability prediction model can be obtained by the data-driven modelling method with the experimental labelled dataset. Experimental verification shows that the proposed method can reduce the number of experiments by more than 60% compared to the existing sampling methods.}, keywords = {Milling; Stability prediction; Data sampling; Data-driven modelling}, year = {2023}, eissn = {1572-8145}, orcid-numbers = {Li, Yingguang/0000-0003-4425-8073} } @article{MTMT:34297929, title = {Cutting Process Consideration in Dynamic Models of Machine Tool Spindle Units}, url = {https://m2.mtmt.hu/api/publication/34297929}, author = {Danylchenko, Yurii and Storchak, Michael and Danylchenko, Mariia and Petryshyn, Andrii}, doi = {10.3390/machines11060582}, journal-iso = {MACHINES}, journal = {MACHINES}, volume = {11}, unique-id = {34297929}, abstract = {Reducing the deviation effect from the specified machining conditions on the quality of the process in real time is the desired result of the intelligent spindle control system. To implement such a control system, a dynamic interaction model of the technological machining system with the cutting process was developed. The transfer matrix method of a multibody system was used in the development of the dynamic model. The physical closure condition of the technological machining system for using the transient matrix method is implemented in the developed model by introducing into this model an additional elastic coupling of the contact between the tool and the machined workpiece. The model is presented as a dynamic model of the elastic system "spindle unit-workpiece/tool-cutting process-tool/workpiece". To develop the dynamic model, the system decomposition was performed with an analytical description of the joint deformation conditions of the subsystems and the use of the transient matrix method to calculate the harmonic influence coefficients of these subsystems. The proposed approach is used to calculate the native vibration frequencies of the spindle with the workpiece fixed in the chuck and supported with the tool. The calculation results correspond to the experimental ones and quite accurately represent their trends for different contact interaction conditions.}, keywords = {Cutting; dynamic model; transfer matrix method; Machine tool; Multibody system; spindle unit}, year = {2023}, eissn = {2075-1702}, orcid-numbers = {Storchak, Michael/0000-0002-6603-1710} } @article{MTMT:33316634, title = {Development of a generalized extended harmonic solution for analyzing the combination of chatter suppression techniques in milling}, url = {https://m2.mtmt.hu/api/publication/33316634}, author = {Defant, Fabrizio and Ghezzi, Daniele and Albertelli, Paolo}, doi = {10.1016/j.jsv.2022.117368}, journal-iso = {J SOUND VIB}, journal = {JOURNAL OF SOUND AND VIBRATION}, volume = {543}, unique-id = {33316634}, issn = {0022-460X}, abstract = {In this paper a comprehensive and structured analysis of the stabilizing properties linked to the combination of different chatter suppression techniques in milling was carried out. Specifically, the spindle speed variation, the stiffness variation and the usage of tools with variable pitch and variable helixangles were considered. For this purpose, a unique, general and efficient frequency domain formulation (extended harmonic solution) was developed. It is suitable for dealing with differential delayed equations characterized by multiple and distributed time dependent delays and time periodic dynamics. It was demonstrated that the developed solution converges to the reference cases, which were studied in literature through semi-discretization and its extensions. Moreover, by selecting a proper number of considered harmonics, the computation time was reduced of one order of magnitude, in the face of a slight reduction of accuracy with respect to time domain approaches. The computed stability lobe diagrams demonstrated that the combination of multi-chatter suppression techniques allows exploiting the best features of each methodology. The simulta-neous use of the spindle speed variation and the stiffness variation was studied for the first time. The absolute limit of stability increased up to 204%, much more than by adopting the techniques in a separate manner. If the enlargement of the stability region is considered as the reference target, the best results were granted by the combination of all the three strategies. Indeed, the improvement with respect to the use of only two techniques was at least 10%.}, keywords = {CHATTER; Milling; spindle speed variation; Delayed systems; Stiffness variation; Linear time periodic dynamics}, year = {2023}, eissn = {1095-8568}, orcid-numbers = {Albertelli, Paolo/0000-0001-5098-0420} } @article{MTMT:33907259, title = {Identification of the process damping coefficient in dry and wet machining of steel}, url = {https://m2.mtmt.hu/api/publication/33907259}, author = {Denkena, Berend and Bergmann, Benjamin and Ellersiek, Lars}, doi = {10.1007/s00170-023-11082-0}, journal-iso = {INT J ADV MANUFACT TECHNOL}, journal = {INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY}, unique-id = {33907259}, issn = {0268-3768}, abstract = {Flank face chamfers are an effective way to suppress vibrations and increase the productivity of milling processes. The underlying process damping mechanism is the so-called indentation effect. The effect describes the process damping as a result of an additional force due to the indentation of workpiece material under the flank face. In literature, this force is commonly modeled by the volume indented under the flank face and a process damping coefficient. To determine the process damping coefficient, various approaches with partly contradictory results exist. In this paper, a novel method to calculate the process damping coefficient based on process forces measurements in orthogonal cutting is applied for steel machining. The method considers ploughing effects of flank face chamfer and cutting edge rounding as well as plastic deformation effects. In the current investigation, the approach is applied to different cooling strategies, chamfer widths, and cutting speeds. The results show that the cutting speed has the most significant influence on the process damping coefficient. With increasing cutting speed, the process damping coefficient increases, which can be attributed to strain rate hardening effects.}, keywords = {Orthogonal cutting; process damping; Metal working fluid; Ploughing force}, year = {2023}, eissn = {1433-3015}, orcid-numbers = {Ellersiek, Lars/0000-0002-1269-0980} } @article{MTMT:33797882, title = {Flip-validated milling process in hardware-in-the-loop environment}, url = {https://m2.mtmt.hu/api/publication/33797882}, author = {Dombóvári, Zoltán and Tóth, Rudolf and Iglesias, A. and Bachrathy, Dániel and Stépán, Gábor}, doi = {10.1016/j.cirp.2023.04.089}, journal-iso = {CIRP ANN-MANUF TECHN}, journal = {CIRP ANNALS-MANUFACTURING TECHNOLOGY}, volume = {72}, unique-id = {33797882}, issn = {0007-8506}, year = {2023}, eissn = {1726-0604}, pages = {369-372}, orcid-numbers = {Dombóvári, Zoltán/0000-0003-2591-3220; Bachrathy, Dániel/0000-0003-1491-1852; Stépán, Gábor/0000-0003-0309-2409} } @article{MTMT:33907267, title = {Coupled LQG with robust control for milling chatter suppression}, url = {https://m2.mtmt.hu/api/publication/33907267}, author = {Du, Jianan and Liu, Xianbo and Long, Xinhua}, doi = {10.1016/j.ijmecsci.2022.108051}, journal-iso = {INT J MECH SCI}, journal = {INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES}, volume = {243}, unique-id = {33907267}, issn = {0020-7403}, abstract = {This paper applies a coupled control method of LQG and robust to suppress milling chatter. With two controllers working together, the coupled control method has strong robustness to reject disturbances. According to this superiority, the time delay item caused by the regenerative effect is regarded as a disturbance for simplifying the system model. Thus the designed controller has a relatively smaller order than other time delay approximation or discretization methods. Based on the designed active control system, simulated results show the coupled control method has better performance than the original LQG and robust control methods. In experiments, the coupled control method improves the average critical cutting depth from 1.5 mm to 6 mm with almost the same control voltage as LQG and robust control methods, while they only improve the corresponding depth to 4.5 mm and 3.5 mm respectively. Furthermore, the stability improvement is also larger than a recently published control method used in milling chatter suppression. The largest stable milling region improvement among these methods shows potential of the coupled control method in milling chatter suppression.}, keywords = {PERFORMANCE; Robust control; Milling chatter suppression; Coupled control; Linear quadratic gaussian (LQG) control}, year = {2023}, eissn = {1879-2162} } @article{MTMT:34297930, title = {Proposal of novel chatter-free milling strategy utilizing extraordinarily numerous flute endmill and high-speed high-power machine tool}, url = {https://m2.mtmt.hu/api/publication/34297930}, author = {Eto, Jun and Hayasaka, Takehiro and Shamoto, Eiji}, doi = {10.1016/j.precisioneng.2022.11.007}, journal-iso = {PRECIS ENG}, journal = {PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY}, volume = {80}, unique-id = {34297930}, issn = {0141-6359}, abstract = {This paper proposes a novel chatter-free milling strategy that utilizes the infinite stable area, i.e., area below the high-speed part of the 0-th lobe, which has not been generally utilized to date. In the conventional methodology, the stable pockets are utilized to realize a high axial depth of cut. However, these pockets tend to shift, e.g., due to long-term deterioration of the spindle, and hence they sometimes cannot be utilized effectively. The proposed strategy combines an extraordinarily numerous flute endmill, e.g., 20 flutes, and a high-performance spindle, e. g., capable of a spindle speed of 33000 min-1, installed on a high-speed high-power machine tool. By increasing the number of flutes, the stability lobes shrink in inverse proportion to that number against the spindle speed and the depth of cut, and the infinite stable area can be utilized in the practical spindle speed zone of recent machine tools. A design method is proposed for the cutting tool and the cutting conditions to utilize this area effectively. Analyses and experiments are conducted to verify the effectiveness of the proposed milling strategy. In the experiments, the material removal rate reaches 2904 cc/min at the spindle speed of 33000 min-1 and the axial depth of cut of 110 mm with no chatter vibration. The infinite stable area is capable of much higher stability and machining ability than the conventionally utilized stable pockets.}, keywords = {CHATTER; high-speed milling; Aircraft structural parts; Numerous flute endmill; 0-th lobe; Infinite stable area}, year = {2023}, eissn = {1873-2372}, pages = {95-103} } @article{MTMT:33570756, title = {Model of force interaction for stability prediction in turning of thin-walled cylindrical workpiece}, url = {https://m2.mtmt.hu/api/publication/33570756}, author = {Falta, Jiří and Sulitka, Maěj and Janota, Miroslav and Frkal, Vojtěch}, doi = {10.1007/s00170-022-10343-8}, journal-iso = {INT J ADV MANUFACT TECHNOL}, journal = {INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY}, volume = {125}, unique-id = {33570756}, issn = {0268-3768}, abstract = {Turning of the thin-walled cylindrical workpiece is technologically highly demanding process due to the high flexibility of the workpiece. In this paper, a mathematical treatment of integral-based model of the cutting force which takes into account feed, cutting speed, depth of cut and tool nose radius leading to a model of tool-workpiece interaction is presented. The force interaction together with the compliant workpiece dynamics leads to a machining stability formulation. The effect of the aforementioned parameters on characteristic exponents is calculated and validated by comparison with experimentally identified exponents. One of the outputs with immediate practical value is identification of the process damping, which is in the studied case shown to be significantly higher than structural damping of the workpiece itself. This means that without loss of reliability in stability prediction the experimental modal analysis of a given workpiece may be omitted and workpiece’s dynamics may be described only by mass and stiffness matrices which can be easily and reliably obtained by a finite element analysis.}, keywords = {Turning; CHATTER; process damping; Machining stability; Thin-walled workpiece}, year = {2023}, eissn = {1433-3015}, pages = {195-212}, orcid-numbers = {Falta, Jiří/0000-0001-8706-4856; Sulitka, Maěj/0000-0001-6649-8954; Janota, Miroslav/0000-0002-6513-200X} } @article{MTMT:34539208, title = {Chatter reliability of high speed cylindrical grinding with uncertain parameters}, url = {https://m2.mtmt.hu/api/publication/34539208}, author = {Feng, Wei and Qin, Peng and Cao, Le and Sun, Cong and Li, Wei and Cao, Xiaojun}, doi = {10.1016/j.jmapro.2023.08.012}, journal-iso = {J MANUFACT PROCES}, journal = {JOURNAL OF MANUFACTURING PROCESSES}, volume = {102}, unique-id = {34539208}, issn = {1526-6125}, year = {2023}, eissn = {2212-4616}, pages = {874-884} } @article{MTMT:33848911, title = {Machine tool calibration: Measurement, modeling, and compensation of machine tool errors}, url = {https://m2.mtmt.hu/api/publication/33848911}, author = {Gao, Wei and Ibaraki, Soichi and Donmez, M. Alkan and Kono, Daisuke and Mayer, J. R. R. and Chen, Yuan -Liu and Szipka, Karoly and Archenti, Andreas and Linares, Jean-Marc and Suzuki, Norikazu}, doi = {10.1016/j.ijmachtools.2023.104017}, journal-iso = {INT J MACH TOOL MANU}, journal = {INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE}, volume = {187}, unique-id = {33848911}, issn = {0890-6955}, abstract = {Advanced technologies for the calibration of machine tools are presented. Kinematic errors independently of their causes are classified into errors within one-axis as intra-axis errors, errors between axes as inter-axis errors, and as volumetric errors. As the major technological elements of machine tool calibration, the measurement methods, modeling theories, and compensation strategies of the machine tool errors are addressed. The criteria for selecting a combination of the technological elements for machine tool calibration from the point of view of accuracy, complexity, and cost are provided. Recent applications of artificial intelligence and machine learning in machine tool calibration are introduced. Remarks are also made on future trends in machine tool calibration.}, keywords = {Measurement; CALIBRATION; UNCERTAINTY; machine learning; Machine tool; Self -calibration}, year = {2023}, eissn = {1879-2170} } @article{MTMT:33907257, title = {Comparison of Signal Processing Techniques for Prediction of Optimal Process Variables to Yield Higher Productivity During Turning on CNC lathe}, url = {https://m2.mtmt.hu/api/publication/33907257}, author = {Gupta, Pankaj and Singh, Bhagat and Shrivastava, Yogesh}, doi = {10.56042/ijems.v1i1.48945}, journal-iso = {INDIAN J ENG MATER S}, journal = {INDIAN JOURNAL OF ENGINEERING AND MATERIALS SCIENCES}, volume = {30}, unique-id = {33907257}, issn = {0971-4588}, abstract = {Tool chatter is one of such occurrences that limits MRR in a number of industries. In the current research, a method to boost output while lowering clatter during turning operations on a CNC lathe has been presented. A microphone is used to record the vibration signals generated during turning tests. The denoised signals are analysed using local mean decomposition (LMD). Disruptions and undesirable embedded ambient noise are removed using wavelet denoising (WD). The product functions that expose chatter information are chosen using these decomposed signals. To recreate the real-time chatter, these well-known PFs are used to reconstruct the signal. A consistent range of turning parameters for greater productivity has been created using the Grey relational analysis (GRA) prediction technique. The measured Chatter Index value has been found to denote steady turning, unstable, and moderate chatter circumstances. In order to confirm the validity of the presented methodology, several tests have been conducted.}, keywords = {CHATTER; Grey relational analysis; Local mean decomposition; Wavelet denoising}, year = {2023}, eissn = {0975-1017}, pages = {103-111} } @article{MTMT:34297923, title = {IDENTIFICATION OF CHATTER VIBRATIONS AND ACTIVE VIBRATION CONTROL BY USING THE SLIDING MODE CONTROLLER ON DRY TURNING OF TITANIUM ALLOY (TI6AL4V)}, url = {https://m2.mtmt.hu/api/publication/34297923}, author = {Guvenc, Mehmet Ali and Bilgic, Hasan Huseyin and Mistikoglu, Selcuk}, doi = {10.22190/FUME210728067G}, journal-iso = {FACTA UNIV SER MECH ENG}, journal = {FACTA UNIVERSITATIS-SERIES MECHANICAL ENGINEERING}, volume = {21}, unique-id = {34297923}, issn = {0354-2025}, abstract = {In recent years, with the development of sensor technologies, communication platforms, cyber-physical systems, storage technologies, internet applications and controller infrastructures, the way has been opened to produce competitive products with high quality and low cost. In turning, which is one of the important processes of machining, chatter vibrations are among the biggest problems affecting product quality, productivity and cost. There are many techniques proposed to reduce chatter vibrations for which the exact cause cannot be determined. In this study, an active vibration control based on the Sliding Mode Control (SMC) has been implemented in order to reduce and eliminate chatter vibration, which is undesirable for the turning process. In this context, three-axis acceleration data were collected from the cutting tool during the turning of Ti6Al4V. Finite Impulse Response (FIR) filtering, Fast Fourier Transform (FFT) analysis and integral process were carried out in order to use the raw acceleration data collected over the system in control. The system is modeled mathematically and an active control block diagram is created. It is observed that chattering decreased significantly after the application of active vibration control. The surface quality formed by the amplitude of the graph obtained after active control has been compared and verified with the data obtained from the actual manufacturing result.}, keywords = {Turning; CHATTER; Ti6Al4V; active vibration control; Sliding Mode Controller}, year = {2023}, eissn = {2335-0164}, pages = {307-322} } @article{MTMT:34539206, title = {Suppressing Milling Chatter of Thin-Walled Parts by Eddy Current Dampers}, url = {https://m2.mtmt.hu/api/publication/34539206}, author = {Hou, Junming and Wang, Baosheng and Hao, Hongyan}, doi = {10.1155/2023/9533689}, journal-iso = {SHOCK VIB}, journal = {SHOCK AND VIBRATION}, volume = {2023}, unique-id = {34539206}, issn = {1070-9622}, year = {2023}, eissn = {1875-9203} } @article{MTMT:34539207, title = {FUNDAMENTAL ANALYSIS ON THE DYNAMIC BEHAVIOR OF TOOLS WITH STRUCTURED FUNCTIONAL SURFACES IN CUTTING OPERATIONS}, url = {https://m2.mtmt.hu/api/publication/34539207}, author = {Jaquet, S. and Baumann, J. and Garcia, R. and Biermann, D.}, doi = {10.17973/MMSJ.2023_11_2023105}, journal-iso = {MM Science Journal}, journal = {MM Science Journal}, volume = {2023}, unique-id = {34539207}, issn = {1803-1269}, year = {2023}, eissn = {1805-0476}, pages = {6872-6880} } @article{MTMT:33848882, title = {Calibration rod selection strategy in RCSA-based method for reliable calculation of milling tool-tip FRFs in rotating conditions}, url = {https://m2.mtmt.hu/api/publication/33848882}, author = {Ji, Yulei and Yu, Yangbo and Bi, Qingzhen and Zhao, Huan}, doi = {10.1016/j.ijmachtools.2023.104016}, journal-iso = {INT J MACH TOOL MANU}, journal = {INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE}, volume = {187}, unique-id = {33848882}, issn = {0890-6955}, abstract = {The measurement of milling tool-tip frequency response functions (FRFs) in rotating conditions is challenging in practice. Methods based on the receptance coupling substructure analysis (RCSA) can obtain rotating tool-tip FRFs using normal modal test devices; thus, they have received extensive attention in the research community. The typical RCSA framework first adopts a calibration rod for measuring rotating FRFs. Then, it analytically calculates the desired tool-tip FRFs through the RCSA theory. As the calculation process involves matrix inversion, high-quality FRF data is required. However, experimentally measured FRFs in rotating structures contain severe noise, leading to an unreliable calculation. This paper presents a novel error analysis model to investigate the propagation mechanism of measurement errors in the typical RCSA framework. Results show that measurement errors would cause errors in the length of the coupled substructure while introducing scaling effects. The calibration rod is found to be vital for RCSA calculation reliability. The patterns of the calculation error are opposed when adopting a short or long calibration rod. Then, a calibration rod selection strategy is proposed. The strategy makes full use of the high measurement quality near the resonance in rotating FRFs and achieves the dominant mode frequency matching between the clamped rod and the clamped tool by adjusting the rod length. Simulations validate the error analysis model and the calibration rod selection strategy. Experimental results also show that the optimal selection of the calibration rod could improve the calculation reliability of rotating tool-tip FRFs in the typical RCSA framework.}, keywords = {RCSA; Rotating tool-tip FRFs; Measurement error analysis; Calibration tool selection}, year = {2023}, eissn = {1879-2170} } @article{MTMT:33879846, title = {Control barrier functionals: Safety-critical control for time delay systems}, url = {https://m2.mtmt.hu/api/publication/33879846}, author = {Kiss, Ádám and Molnár, Tamás Gábor and Ames, A.D. and Orosz, Gábor}, doi = {10.1002/rnc.6751}, journal-iso = {INT J ROBUST NONLIN}, journal = {INTERNATIONAL JOURNAL OF ROBUST AND NONLINEAR CONTROL}, volume = {33}, unique-id = {33879846}, issn = {1049-8923}, year = {2023}, eissn = {1099-1239}, pages = {7282-7309}, orcid-numbers = {Kiss, Ádám/0000-0002-7074-4553; Molnár, Tamás Gábor/0000-0002-9379-7121} } @article{MTMT:34297919, title = {Chatter suppression in diamond turning using magnetic field assistance}, url = {https://m2.mtmt.hu/api/publication/34297919}, author = {Li, Denghui and Yip, Wai Sze and Cao, Hongrui and Zhang, Hanqian and Tang, Yuk Ming and To, Suet}, doi = {10.1016/j.jmatprotec.2023.118150}, journal-iso = {J MATER PROCESS TECH}, journal = {JOURNAL OF MATERIALS PROCESSING TECHNOLOGY}, volume = {321}, unique-id = {34297919}, issn = {0924-0136}, abstract = {During diamond turning of difficult-to-cut materials in ultra-precision machining, the self-excited vibration (i.e., chatter) is a severe problem that reduces the machining quality of workpieces and accelerates tool wear. In this work, a magnetic field-assisted cutting strategy is developed to suppress chatter during diamond turning of titanium alloys. Considering the radius of the tool nose and the process damping force, the stability of the diamond turning system is investigated. Based on that, the improvement effect of the magnetic field on the system's stability through the eddy current damping effect is analyzed. Diamond-turning experiments with and without magnetic field assistance are carried out under various cutting conditions. The experimental results, which include cutting forces, frequency spectra correlating to the cutting forces, and surface morphologies, indicate that the magnetic field assistance successfully suppresses chatter during diamond turning. The machined surface quality of the workpiece is improved.}, keywords = {magnetic field; Chatter suppression; Difficult-to-cut materials; Ultra-precision machining; Diamond turning}, year = {2023}, eissn = {1873-4774}, orcid-numbers = {Tang, Yuk Ming/0000-0001-8215-4190} } @article{MTMT:34539201, title = {Dynamics modeling and simultaneous identification of force coefficients for variable pitch bull-nose cutter milling considering process damping and cutter runout}, url = {https://m2.mtmt.hu/api/publication/34539201}, author = {Li, Shikang and Zhan, Danian and Sun, Shuoxue and Sun, Yuwen}, doi = {10.1007/s00170-023-12777-0}, journal-iso = {INT J ADV MANUFACT TECHNOL}, journal = {INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY}, volume = {1}, unique-id = {34539201}, issn = {0268-3768}, year = {2023}, eissn = {1433-3015}, pages = {1} } @article{MTMT:33570704, title = {Chatter-free and high-quality end milling for thin-walled workpieces through a follow-up support technology}, url = {https://m2.mtmt.hu/api/publication/33570704}, author = {Liu, Sijiang and Xiao, Juliang and Tian, Yu and Ma, Shijun and Liu, Haitao and Huang, Tian}, doi = {10.1016/j.jmatprotec.2023.117857}, journal-iso = {J MATER PROCESS TECH}, journal = {JOURNAL OF MATERIALS PROCESSING TECHNOLOGY}, volume = {312}, unique-id = {33570704}, issn = {0924-0136}, year = {2023}, eissn = {1873-4774} } @article{MTMT:33907262, title = {Rounding mechanism of a novel double-disc arc-contact lapping for high-precision rollers}, url = {https://m2.mtmt.hu/api/publication/33907262}, author = {Liu, Weifeng and Ren, Chengzu and Chen, Guang and Zhang, Jing and Hao, Yiwen and He, Chunlei}, doi = {10.1007/s00170-023-11014-y}, journal-iso = {INT J ADV MANUFACT TECHNOL}, journal = {INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY}, unique-id = {33907262}, issn = {0268-3768}, abstract = {Centerless grinding is the main technology for mass processing of rotary parts, which can improve the roundness of rotary parts. With the demand for higher levels of roundness accuracy (within 0.3 mu m), the development and operating costs of centerless grinding machines have increased dramatically. Taking cylindrical roller of bearing as research object, a new lapping process of double-disc arc-contact lapping (DDACL) is presented in this work. On the processing mechanism, it is expounded how DDACL overcomes the three fundamental technical difficulties of centerless grinding process in geometric lobing, workpiece instability and work-regenerative chatter vibration, and the unique rounding mechanism of DDACL process is established. At the same time, the machine has simple structure, low precision requirement, and low cost. After lapping with 45 steel groove on the developed test bench, the roundness accuracy of the cylindrical roller is effectively controlled within 0.2 mu m, and the accuracy of some rollers can even reach 130 nm, which has significant precision advantages. According to the established DDACL rounding mechanism, the influence of 45 steel and PTFE groove material and electromagnetic driving force on the rounding speed of parts in the test is well explained. The process method proposed in this work paves the way for improving the roundness accuracy of other rotary parts, such as those seen in tapered roller and spherical roller.}, keywords = {Roundness; lapping; cylindrical rollers; Centerless grinding; Precision evolution}, year = {2023}, eissn = {1433-3015}, orcid-numbers = {Chen, Guang/0000-0003-0336-0100} } @article{MTMT:34297918, title = {Analysis and Development of the CFRP Boring Bar for Stability Improvement}, url = {https://m2.mtmt.hu/api/publication/34297918}, author = {Lu, Licheng and Ni, Can and Liu, Gang and Qian, Bo and An, Qinglong and Cao, Zhenzhen and Zhang, Liqiang and Li, Junli}, doi = {10.1007/s12221-023-00376-5}, journal-iso = {FIBER POLYM}, journal = {FIBERS AND POLYMERS}, unique-id = {34297918}, issn = {1229-9197}, abstract = {Boring bars with a large length-to-diameter ratio have become increasingly indispensable for deep hole machining. However, the dynamic performance of conventional boring bars may be inadequate, resulting in vibrations. In this paper, a novel boring bar with composites and a constrained layer damping structure was fabricated to suppress vibrations during the boring operation. Initially, the configuration of the CFRP boring bar was proposed based on theoretical analysis, and then the modal parameters were calculated using the bending strain energy method and cantilever beam theory. Subsequently, the geometric design parameters were optimized analytically using the finite element method. Modal and cutting tests were then conducted to evaluate the cutting stability of a CFRP boring bar with a length-to-diameter ratio of 8.4. The modal parameters, vibration signals, and cutting force signals were measured and compared with a carbide boring bar. The experimental results indicated that there was a significant improvement in the cutting stability of the CFRP boring bar.}, keywords = {CHATTER STABILITY; CFRP; Dynamic characteristic; Constrained layer damping; Boring bar}, year = {2023}, eissn = {1875-0052} } @article{MTMT:34297931, title = {Sliding velocity dependence of kinetic friction coefficient of bronze-filled polytetrafluoroethylene and its application to robustness improvement of friction damper}, url = {https://m2.mtmt.hu/api/publication/34297931}, author = {Maegawa, Satoru and Inagaki, Hiroki and Liu, Xiaoxu and Itoigawa, Fumihiro}, doi = {10.1299/mej.22-00254}, journal-iso = {MECHANICAL ENGINEERING JOURNAL}, journal = {MECHANICAL ENGINEERING JOURNAL}, unique-id = {34297931}, issn = {2187-9745}, abstract = {This study demonstrates that the robustness of friction dampers can be enhanced by using the positive velocity dependence of the kinetic friction force. First, we show that the kinetic friction coefficient can be reduced under extremely low sliding velocity conditions by using oleyl acid phosphate (OLAP) as an additive to the lubricant on the sliding surfaces between bronze-filled polytetrafluoroethylene (PTFE) and steel. Next, based on the results of the numerical simulations, we show that the use of a sliding surface with a positive velocity dependence of the friction coefficient is effective in improving the vibration reduction ability of the friction dampers. Finally, our findings are demonstrated through a simplified experiment.}, keywords = {Vibration control; Friction damper; Velocity dependence of friction coefficient}, year = {2023} } @article{MTMT:34297922, title = {A fully analytical nonlinear dynamic model of spindle-holder-tool system considering contact characteristics of joint interfaces}, url = {https://m2.mtmt.hu/api/publication/34297922}, author = {Miao, Huihui and Li, Changyou and Yu, Chunping and Hua, Chunlei and Wang, Chenyu and Zhang, Xiulu and Xu, Mengtao}, doi = {10.1016/j.ymssp.2023.110693}, journal-iso = {MECH SYST SIGNAL PR}, journal = {MECHANICAL SYSTEMS AND SIGNAL PROCESSING}, volume = {202}, unique-id = {34297922}, issn = {0888-3270}, abstract = {The productivity, surface finish, and dimensional accuracy during machining are directly related to the vibration characteristics of tool tip. Moreover, the dynamics of tool tip is not only determined by the flexibility of tool, collet, holder and spindle, but also depends on the contact characteristics of joint interfaces. This paper proposes a fully analytical model of the spindleholdertool system considering the nonlinear contact characteristics of joint interfaces. The dynamics of spindle, holder, collet and tool are modeled applying Timoshenko beam theory considering the combined shear and rotational effects, in which the tapered sections of spindle, holder and collet are modeled using multi-stepped beam to account for the taper effect. Under highly dynamic cutting load, the variation in the spacing of joint interfaces will induce the changes in the contact characteristics due to the corresponding vibrations. Therefore, the contact behaviors of spindle/holder, collet/holder, collet/nut, and tool/collet interfaces are analytically modeled using the distributed nonlinear spring-damping layers. The fractal theory and the slicing method are applied to derive the vibration displacement-dependent stiffness matrix of nonlinear springs in joint interfaces considering the surface morphology, geometry, material properties, and locking force of joint interfaces. Furthermore, the five degree of freedom (DOF) nonlinear stiffness model of the spindle-bearing joint dependent on vibration displacement is also considered. The effectiveness of the established analytical dynamic model is verified through vibration testing and modal hammering experiments. The changes in the vibration characteristics by considering the connection ways of joint interfaces, the fractal parameters of joint interfaces and the rotation speed are also investigated. The developed model can provide some theoretical principles for the optimization at design stage without prototypes.}, keywords = {Surface topography; fractal theory; Spindle-holder-tool system; Joint interfaces; Distributed nonlinear spring-damping layer}, year = {2023}, eissn = {1096-1216} } @article{MTMT:34297921, title = {Experimental Setup for In-Process Measurements and Analysis of Wear-Dependent Surface Topographies}, url = {https://m2.mtmt.hu/api/publication/34297921}, author = {Potthoff, Nils and Liss, Jan and Wiederkehr, Petra}, doi = {10.1115/1.4063133}, journal-iso = {J MANUF SCI E-T ASME}, journal = {JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME}, volume = {145}, unique-id = {34297921}, issn = {1087-1357}, abstract = {High-strength and corrosion-resistant materials, such as the nickel-based superalloy Inconel 718, are widely used in the energy and aerospace industries. However, machining these materials results in high process forces and significant tool wear. This tool wear negatively influences the resulting surface topography. Nevertheless, the accuracy requirements for functional surfaces are extremely high. Simulation systems can be used to design these processes. However, time-consuming and cost-intensive experiments often have to be conducted to develop and parameterize the required models. To overcome this problem, an analogy test setup for in-process measurements of wear-dependent properties was developed, which allows a multi-level evaluation of the process. By combining different measurement techniques, wear-dependent process characteristics can be determined and analyzed, which is usually only possible for initial and final conditions requiring a significant measurement effort.}, keywords = {sensors; Optical Metrology; TOOL WEAR; Inconel 718; machining processes; in-process surface measurement; analogy test rig}, year = {2023}, eissn = {1528-8935} } @article{MTMT:34539122, title = {Research Advances in Chatter of Metal Cutting Systems Involving Time Delays}, url = {https://m2.mtmt.hu/api/publication/34539122}, author = {Ren, Yongsheng and Yao, Donghui and Zhang, Jinfeng}, journal-iso = {CHINA MECH ENG}, journal = {ZHONGGUO JIXIE GONGCHENG / CHINA MECHANICAL ENGINEERING}, volume = {34}, unique-id = {34539122}, issn = {1004-132X}, year = {2023}, pages = {2548-2567,2576} } @article{MTMT:33893572, title = {A review on methods for obtaining dynamical property parameters of machining processes}, url = {https://m2.mtmt.hu/api/publication/33893572}, author = {Ren, Yuan-Yuan and Wan, Min and Zhang, Wei-Hong and Yang, Yun}, doi = {10.1016/j.ymssp.2023.110280}, journal-iso = {MECH SYST SIGNAL PR}, journal = {MECHANICAL SYSTEMS AND SIGNAL PROCESSING}, volume = {194}, unique-id = {33893572}, issn = {0888-3270}, abstract = {Accurately obtaining dynamical parameters in relation to machining processes is extremely crucial to predict stability lobe diagrams (SLDs), which are used to plan chatter-free cutting parameters. Existing progress reviews on machining chatter mainly focus on the methods for detecting, monitoring and predicting chatter, especially including algorithms for predicting SLDs. However, a comprehensive review of techniques oriented for obtaining dynamical parameters during machining processes is still desired. This article presents a systematic review on typical means for obtaining typical dynamical parameters, and provides adequate guidance for studying the chatter problem of machining processes. Experiment-based feature collecting and theoretically formulating methodologies for figuring out dynamical parameters are outlined and compared with each other. Comments and discussions are conducted by deeply reviewing relevant methods for obtaining FRFs of the tool-holder-spindle system, property parameters of the process damping and FRFs of the thin-walled workpiece. Kernel procedures and key algorithms for evaluating dynamical parameters are provided. Advantages and disadvantages of different methods are analyzed. Finally, challenges for obtaining dynamical parameters are discussed, and potential research directions are suggested. Appropriate techniques for obtaining dynamical parameters will certainly enhance the accuracy of the predicted SLDs for developing chatter suppressing means in various machining operations.}, keywords = {process damping; machining processes; Stability lobe diagrams (SLDs); Frequency response functions (FRFs); Ploughing force coefficients}, year = {2023}, eissn = {1096-1216} } @article{MTMT:34297924, title = {A framework for hybrid manufacturing cost minimization and preform design}, url = {https://m2.mtmt.hu/api/publication/34297924}, author = {Schmitz, Tony and Corson, Gregory and Olvera, David and Tyler, Christopher and Smith, Scott}, doi = {10.1016/j.cirp.2023.04.051}, journal-iso = {CIRP ANN-MANUF TECHN}, journal = {CIRP ANNALS-MANUFACTURING TECHNOLOGY}, volume = {72}, unique-id = {34297924}, issn = {0007-8506}, abstract = {This paper describes preform design optimization in hybrid additive-subtractive manufacturing. In hybrid manufacturing, the question of what form and what geometry the additive preform should take has largely been a matter of intuition and experience, or trial and error. The choice of a more optimal preform depends on the target parameters, such as stiffness, cost, or lead time. We demonstrate a framework for preform opti-mization using static stiffness, and then the combined cost of additive and subtractive manufacturing, while respecting stable cutting conditions for the tool-part combination. The procedure is illustrated by comparing three preform geometries for a thin wall. & COPY; 2023 CIRP. Published by Elsevier Ltd. All rights reserved.}, keywords = {Optimization; hybrid manufacturing; Preform}, year = {2023}, eissn = {1726-0604}, pages = {373-376} } @article{MTMT:33230432, title = {Review and status of tool tip frequency response function prediction using receptance coupling}, url = {https://m2.mtmt.hu/api/publication/33230432}, author = {Schmitz, Tony and Betters, Emma and Budak, Erhan and Yuksel, Esra and Park, Simon and Altintas, Yusuf}, doi = {10.1016/j.precisioneng.2022.09.008}, journal-iso = {PRECIS ENG}, journal = {PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY}, volume = {79}, unique-id = {33230432}, issn = {0141-6359}, abstract = {This paper provides a chronological review of publications that implement and advance the receptance coupling substructure analysis (RCSA) approach first applied to tool tip receptance (or frequency response function) prediction for milling applications in 2000. The review topics mimic the RCSA approach, where the tool, holder, and spindle-machine receptances are coupled analytically, and include: tool-holder receptance modeling; connection modeling; spindle-machine receptances; and applications. The review paper summarizes contributions from multiple, international authors (198 papers) to these topics. It also provides a comprehensive resource for those beginning an investigation into RCSA.}, keywords = {DYNAMICS; Machining; Milling; Frequency response function; Receptance coupling}, year = {2023}, eissn = {1873-2372}, pages = {60-77} } @article{MTMT:34242592, title = {Stability and Bifurcation Analysis in Turning of Flexible Parts with Spindle Speed Variation Using FEM Simulation Data}, url = {https://m2.mtmt.hu/api/publication/34242592}, author = {Shamei, Mahdi and Tajalli, Seyed Ahmad}, doi = {10.1142/S0219455424500044}, journal-iso = {INT J STRUCT STAB DY}, journal = {INTERNATIONAL JOURNAL OF STRUCTURAL STABILITY AND DYNAMICS}, unique-id = {34242592}, issn = {0219-4554}, abstract = {This study investigates the effect of variable spindle speed with sinusoidal modulation on chatter vibrations generated in turning of flexible parts. The Euler-Bernoulli beam theory is assumed for mathematical modeling of the slender workpiece that is clamped at the chuck and pinned at the tailstock. The induced force as interaction between tool and workpiece (A2024-T351) during chip formation is calculated using finite element simulation. Numerical-based semi-discretization approach is utilized to seek stability regions and chatter frequencies regarding coupled dynamic model of tool and workpiece, in the form of delay differential equations with time varying delay term. The simulated data are validated and compared with those for a rigid part. The results indicate the efficiency of periodic modulation in improvement of machining stability especially for low spindle speeds. The stability charts for different interaction location and also time history response are studied, extensively. Finally, detection of period-one, flip and secondary Hopf bifurcations for different spindle speeds at instability borders are analyzed and discussed by solving corresponding eigenvalue problem.}, keywords = {bifurcations; Semi-discretization; CHATTER STABILITY; Variable spindle speed; flexible part}, year = {2023}, eissn = {1793-6764}, orcid-numbers = {Tajalli, Seyed Ahmad/0000-0002-9250-9933} } @article{MTMT:34297933, title = {Machining performance on AISI 304 steel in the milling machine with mechanical and hydraulic spindle}, url = {https://m2.mtmt.hu/api/publication/34297933}, author = {Shirazi, Mehdi and Najafabadi, Akbar Hojjati and Amini, Saeid}, doi = {10.1177/09544089231156690}, journal-iso = {P I MECH ENG E-J PRO}, journal = {PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART E-JOURNAL OF PROCESS MECHANICAL ENGINEERING}, unique-id = {34297933}, issn = {0954-4089}, abstract = {Milling machines are widely used for producing a range of products used across various industries such as mold and dies, consumer products, automotive, etc. One of the main components of a milling machine is the spindle drive. The spindle essentially provides the rotational movement of the cutting tool and the power required for material cutting. Commonly, a servo or gearbox electric motor is used for powering the spindle. An alternative method is to use a hydraulic-powered motor. In this study, a hydraulic-powered spindle is developed and installed on a milling machine. Analysis of the milling process with the hydraulic spindle as well as the determination of machining parameters is compared with the conventional mechanical spindle. Mechanical spindles have disadvantages such as unstable spindle speeds under different operating conditions, mechanical impedance in gears, and thermal stress problems, which can have negative effects on part surface quality and cutting forces. On the other hand, the hydraulic spindle has advantages, such as higher stability, higher performance accuracy, and thermal stress removal, which may be the main factors in this study. Milling experiments were performed using AISI 304 stainless steel to compare the performance of the hydraulic spindle with the mechanical spindle in terms of surface roughness and cutting forces. Three factors including spindle rotational speed, feed rate, and depth of cut were selected as input parameters. The results showed that surface roughness and cutting force in hydraulic spindle milling improved significantly compared to that from the mechanical spindle.}, keywords = {Surface roughness; Cutting forces; Milling; mechanical spindle; hydraulic spindle}, year = {2023}, eissn = {2041-3009}, orcid-numbers = {Najafabadi, Akbar Hojjati/0000-0003-1308-9123; Amini, Saeid/0000-0003-4650-707X} } @article{MTMT:33848886, title = {A novel high-order discretization method for the milling stability prediction considering the differential of directional cutting coefficient and vibration velocities}, url = {https://m2.mtmt.hu/api/publication/33848886}, author = {Song, Chunlei}, doi = {10.1007/s00170-023-11013-z}, journal-iso = {INT J ADV MANUFACT TECHNOL}, journal = {INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY}, unique-id = {33848886}, issn = {0268-3768}, abstract = {A novel high-order discretization method for the prediction of milling stability is proposed in this paper to increase the accuracy and efficiency considering the differential of directional cutting coefficient and vibration velocities. Same to the existing full-discretization method (FDM) and semi-discretization method (SDM), the milling system is expressed as a linear time-periodic equation and the time period is discretized into discrete time intervals to approximate the solution. In this algorithm, the cutting force coefficient matrix of the whole integrand is reconstructed to lay the foundation for the fast and accurate approximation. Then, the monodromy matrix (or the Floquet matrix) is calculated by the method used in the temporal finite element analysis (TFEA) instead of the multiple recursive algorithms which can improve the computational time. Finally, the computational efficiency is defined in a new way which gives quantitative comparisons for different discretization methods. It is shown that the proposed method can reduce the computational cost by 91-95% when the same errors are required.}, keywords = {Floquet theory; REGENERATIVE CHATTER; Milling stability; matrix reconstruction}, year = {2023}, eissn = {1433-3015}, orcid-numbers = {Song, Chunlei/0000-0002-6517-1893} } @article{MTMT:33907265, title = {Optimization of Milling Processes: Chatter Detection via a Sensor-Integrated Vice}, url = {https://m2.mtmt.hu/api/publication/33907265}, author = {Stavropoulos, Panagiotis and Souflas, Thanassis and Manitaras, Dimitris and Papaioannou, Christos and Bikas, Harry}, doi = {10.3390/machines11010052}, journal-iso = {MACHINES}, journal = {MACHINES}, volume = {11}, unique-id = {33907265}, abstract = {The future of the milling process is the fully autonomous operation of the machine tools. Developments in terms of automation and machine tool design are now enabling fully autonomous operation. However, the optimization and stability of the process itself still remains a challenge. Chatter is the most significant bottleneck, and as such, it should be constantly monitored to ensure a stable process. This work proposes a sensor-integrated milling vice using an MEMS accelerometer as a non-invasive monitoring solution for chatter detection. The system is comprised by low-cost, industrial-grade components suitable for implementation in real production scenarios. The dynamic analysis of the sensor-integrated vice enables the definition of the sensor-integration point to ensure measurement quality. The use of advanced signal process algorithms for the demodulation of the vibration signal, along with the use of artificial intelligence for chatter detection, led to a high-performance system at a low cost. A wide set of milling experiments that has been conducted showcased that the proposed solution enables continuous, real-time process optimization in milling through in-process chatter detection.}, keywords = {Modal analysis; Chatter detection; machining monitoring; sensor-integrated tooling; digital machining}, year = {2023}, eissn = {2075-1702}, orcid-numbers = {Souflas, Thanassis/0000-0002-4582-3559; Bikas, Harry/0000-0003-2919-1659} } @article{MTMT:33848883, title = {A State-of-the-Art Review on Chatter Stability in Machining Thin-Walled Parts}, url = {https://m2.mtmt.hu/api/publication/33848883}, author = {Sun, Yuwen and Zheng, Meng and Jiang, Shanglei and Zhan, Danian and Wang, Ruoqi}, doi = {10.3390/machines11030359}, journal-iso = {MACHINES}, journal = {MACHINES}, volume = {11}, unique-id = {33848883}, abstract = {Thin-walled parts are widely used in many important fields because of performance and structural lightweight requirements. They are critical parts because they usually carry the core functions of high-end equipment. However, their high-performance machining has been facing severe challenges, among which the dynamics problem is one of the most important obstacles. The machining system is easily subjected to chatter due to the weak rigidity of the thin-walled structure and slender cutting tool, which significantly deteriorates the surface quality and reduces the machining efficiency. Extensive studies aiming at eliminating machining chatter have been carried out in the recent decades. This paper systematically reviews previous studies on the identification of system dynamic characteristics, modeling and prediction of chatter stability, and chatter elimination/suppression methods and devices. Finally, existing problems are summarized, and future research is concluded.}, keywords = {DYNAMICS; Machining; SUPPRESSION; Thin-walled parts; Slender cutting tool; chatter elimination}, year = {2023}, eissn = {2075-1702} } @article{MTMT:34406974, title = {ROBOT ASSISTED STABILIZATION FOR FLEXIBLE WORKPIECES SUBJECTED TO HIGHLY INTERRUPTED CUTTING}, url = {https://m2.mtmt.hu/api/publication/34406974}, author = {Tóth, Rudolf and Stépán, Gábor}, doi = {10.17973/MMSJ.2023_11_2023114}, journal-iso = {MM Science Journal}, journal = {MM Science Journal}, volume = {2023-November}, unique-id = {34406974}, issn = {1803-1269}, year = {2023}, eissn = {1805-0476}, pages = {6938-6944}, orcid-numbers = {Stépán, Gábor/0000-0003-0309-2409} } @article{MTMT:33989207, title = {Bifurcation scenarios in the hardware-in-the-loop experiments of highly interrupted milling processes}, url = {https://m2.mtmt.hu/api/publication/33989207}, author = {Tóth, Rudolf and Stépán, Gábor}, doi = {10.1007/s11071-023-08591-8}, journal-iso = {NONLINEAR DYNAM}, journal = {NONLINEAR DYNAMICS}, volume = {111}, unique-id = {33989207}, issn = {0924-090X}, abstract = {Hardware-in-the-loop (HIL) measurements of highly interrupted milling processes were conducted. A real spindle was used with a dummy tool on which the cutting forces were emulated with contactless sensors and actuators. During the experiments, Hopf- and period-doubling bifurcations were identified. The nonlinear dynamics of these period-doubling bifurcations are analyzed for a discrete model of highly interrupted milling. This investigation found the bifurcation to be subcritical, which draws the attention to the limited practical validity of linear stability analysis.}, year = {2023}, eissn = {1573-269X}, pages = {22177-22184}, orcid-numbers = {Stépán, Gábor/0000-0003-0309-2409} } @article{MTMT:33907263, title = {Superior optimal inverse filtering of cutting forces in milling of thin-walled components}, url = {https://m2.mtmt.hu/api/publication/33907263}, author = {Totis, G. and Sortino, M.}, doi = {10.1016/j.measurement.2022.112227}, journal-iso = {MEASUREMENT}, journal = {MEASUREMENT}, volume = {206}, unique-id = {33907263}, issn = {0263-2241}, abstract = {Measuring the cutting force when milling slender/thin-walled parts is difficult because of the large and long-lasting structural vibrations that cause inertial disturbances in the measured signals. Under these conditions, signal filtering is the only option to significantly extend the dynamic bandwidth of the device above 3 kHz. Non-parametric filters are typically preferred over parametric ones because they are more practical and easier to apply in industrial applications. Currently available parametric filters cannot address this problem because they are based on oversimplified transmissibility models or are affected by computational problems when the impulse responses of the device are excessively long. In this study, the novel non-parametric Superior Optimal Inverse Filter was developed to address the limitations of state-of-the-art filters. It is a non-trivial extension of the Optimal Inverse Filter to a higher dimensionality, and it can process long transients and generic (possibly aperiodic) signals. Thus, outstanding results were obtained both from modal analysis and from an actual case study, demonstrating the potential of the new filter for an effective and almost completely automatic cutting force dynamic compensation when milling thin-walled structures. The proposed filter was compared with parametric Kalman filters and with the existing non-parametric filters, and it offered a considerably better performance, particularly for compensating for cross disturbances and for input force position-dependent dynamics.}, keywords = {DYNAMICS; COMPENSATION; Cutting forces; Milling; dynamometer}, year = {2023}, eissn = {1873-412X} } @article{MTMT:34248645, title = {Increasing tool life and machining performance by dynamic spindle speed control along toolpaths for milling complex shape parts}, url = {https://m2.mtmt.hu/api/publication/34248645}, author = {Vavruska, Petr and Bartos, Filip and Stejskal, Michal and Pesice, Matej and Zeman, Pavel and Heinrich, Petr}, doi = {10.1016/j.jmapro.2023.04.058}, journal-iso = {J MANUFACT PROCES}, journal = {JOURNAL OF MANUFACTURING PROCESSES}, volume = {99}, unique-id = {34248645}, issn = {1526-6125}, abstract = {This paper focuses on dynamic spindle speed and feed rate control to increase tool life and reduce machining time during milling of complex shaped parts. Machining of complex shaped surfaces is one of the most demanding machining applications, especially if the workpiece is made of difficult-to-cut material. Tool life needs to be considered during selection of cutting conditions. Both feed rate and cutting speed also have a direct effect on the resulting roughness and accuracy. When machining with tools with a circular cutting edge, such as ball or toroidal mills, the real cutting diameter of the tool changes continuously and as a result the cutting speed along the toolpath also changes continuously. Therefore a new method to compute the required spindle speed and feed rate was proposed based on the implemented kinematic parameters of a real spindle controller. In addition, a method to calculate the effective cutting radius of the tool based on the actual height of the remaining material was proposed to achieve a constant cutting speed through dynamic spindle speed control. The benefits of using the new optimization method were verified when machining a duplex stainless steel (1.4462) part. This test confirmed that the new optimization method results in a significant increase in tool life as well as a sig-nificant saving of machining time, while achieving the desired surface quality.}, keywords = {Tool life; Feed Rate; Spindle speed; complex shape; Cutting radius; Point milling}, year = {2023}, eissn = {2212-4616}, pages = {283-297} } @article{MTMT:33167902, title = {A state-of-the-art review on robotic milling of complex parts with high efficiency and precision}, url = {https://m2.mtmt.hu/api/publication/33167902}, author = {Wang, Wenbo and Guo, Qiang and Yang, Zhibo and Jiang, Yan and Xu, Jinting}, doi = {10.1016/j.rcim.2022.102436}, journal-iso = {ROBOT CIM-INT MANUF}, journal = {ROBOTICS AND COMPUTER-INTEGRATED MANUFACTURING}, volume = {79}, unique-id = {33167902}, issn = {0736-5845}, abstract = {Milling refers to a class of material processing methods that relies on a high-speed rotating milling cutter removing extra material to get desired shapes and features. Being distinct from conventional material removal techniques, like CNC machining, robotic milling has the benefits of lower cost, higher flexibility, better adapt-ability, etc. Therefore, robotic milling has attracted a large amount of researchers' interest and become an important material-removing way in the machining of complex parts. Trying to present a comprehensive and systematic review on the robotic milling of complex components, this paper elaborates the history and state of the art on stiffness, dynamics, posture planning, chatter, and compensation in the robotic milling process. Furthermore, future potential research topics about robotic milling are also discussed.}, keywords = {COMPENSATION; CHATTER; STIFFNESS; Dynamics model; COMPLEX COMPONENTS; Robotic milling}, year = {2023}, eissn = {1879-2537} } @article{MTMT:34242593, title = {Milling chatter detection based on information entropy of interval frequency}, url = {https://m2.mtmt.hu/api/publication/34242593}, author = {Wan, Shaoke and Liu, Shuo and Li, Xiaohu and Yan, Ke and Hong, Jun}, doi = {10.1016/j.measurement.2023.113328}, journal-iso = {MEASUREMENT}, journal = {MEASUREMENT}, volume = {220}, unique-id = {34242593}, issn = {0263-2241}, abstract = {Chatter has been one of the most unfavorable issues during the milling, seriously affecting the machining efficiency, quality of machined surface. In this paper, considering the distribution characteristics of multiple chatter frequencies for milling process, a chatter detection method based on the information entropy of interval frequency (IFIE) is proposed. The matrix notch filter is first utilized to filter out the harmonics of spindle rotating frequency and possible colored noise components. Then the main components of filtered signals are estimated with a subspace-based technique. Specially, interval frequency (IF) that denotes the distance between estimated frequencies to the nearest harmonics of spindle rotating frequency is proposed, and then the chatter indicator IFIE is developed by constructing the histogram of IFs. Finally, the milling experiments under various conditions are utilized to validate the proposed methodology, and the results show that the chatter at early stage can be accurately and timely detected.}, keywords = {Frequency estimation; information entropy; Milling chatter detection; Interval frequency}, year = {2023}, eissn = {1873-412X} } @article{MTMT:34297920, title = {Fundamental investigation on process damping potentials of cutting tools with flank face chamfers}, url = {https://m2.mtmt.hu/api/publication/34297920}, author = {Woste, Florian and Platt, Timo and Baumann, Jonas and Biermann, Dirk and Wiederkehr, Petra}, doi = {10.1016/j.cirpj.2023.08.012}, journal-iso = {CIRP J MANUF SCI TECHNOL}, journal = {CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY}, volume = {47}, unique-id = {34297920}, issn = {1755-5817}, abstract = {The effect of process damping in machining is an effective influencing factor for the suppression of regenerative chatter vibrations. Although process damping is typically associated with process configurations at low cutting speeds, the use of tools with flank face chamfers is a suitable strategy to specifically increase process stability over a wide range of cutting speeds. In this contribution, damping potentials of different chamfer designs were evaluated. Using an analogy setup providing defined, high-frequency tool oscillations, fundamental interrelations of the dynamic chamfer-workpiece contact were characterized. The results illustrate the impact of specific chamfer designs on process damping and the significance of the elastic material response on the tool-workpiece interaction.(c) 2023 CIRP.}, keywords = {Cutting; process damping; Flank face chamfer}, year = {2023}, eissn = {1755-5817}, pages = {7-17}, orcid-numbers = {Platt, Timo/0000-0003-0252-9461; Biermann, Dirk/0000-0001-8215-0093} } @article{MTMT:34242595, title = {Investigation of the low-frequency chatter in robotic milling}, url = {https://m2.mtmt.hu/api/publication/34242595}, author = {Xin, Shihao and Tang, Xiaowei and Wu, Jiawei and Peng, Fangyu and Yan, Rong and Yang, Wei}, doi = {10.1016/j.ijmachtools.2023.104048}, journal-iso = {INT J MACH TOOL MANU}, journal = {INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE}, volume = {190}, unique-id = {34242595}, issn = {0890-6955}, abstract = {In robotic milling with large allowance process, low-frequency chatter (LFC) is an important factor observed in high-speed and low-speed milling, affecting the processing efficiency and quality. Previous research has used the regenerative chatter theory, ignoring modulated tool-workpiece engagement conditions, or mode coupling theory under the assumption of threading operations to explain the LFC mechanism and predict the stability boundary. However, these models overlook or inaccurately characterize the modulation effect, leading to inaccurate modeling of dynamic chip thickness changes during milling, making it difficult to understand the mechanism of LFC. Here, we propose an LFC stability model that considers modulated tool-workpiece engagement conditions and the mode coupling effect of the robotic structure for robotic milling. This approach allows us to reveal the mechanism of LFC and identify the characteristic signal of low-frequency vibration, which is the sideband frequency signal. Initially, the evolution of LFC is analyzed, and its characteristics are summarized. Further, a surface renewal (SR) model is proposed to accurately calculate the dynamic cutting force caused by modulated tool-workpiece engagement conditions in LFC. Furthermore, the LFC stability model, considering the modulated tool-workpiece engagement conditions and mode coupling effect, is established based on impulse response function (IRF) method. Finally, we verify the accuracy of our model through milling experiments and compare it with that of the classical stability prediction model. Our results show that LFC is highly dependent on speed, and our stability model can effectively predict the stability boundary of LFC in robotic milling with large allowance process.}, keywords = {conditions; Robotic milling; Regenerative effect; Mode coupling effect; Low -frequency chatter; Modulated tool-workpiece engagement}, year = {2023}, eissn = {1879-2170}, orcid-numbers = {Wu, Jiawei/0000-0003-1044-1259} } @article{MTMT:33167891, title = {An efficient and accurate chatter prediction method of milling processes with a transition matrix reduction scheme}, url = {https://m2.mtmt.hu/api/publication/33167891}, author = {Yang, Yun and Yuan, Jia-Wei and Tie, Duo and Wan, Min and Zhang, Wei-Hong}, doi = {10.1016/j.ymssp.2022.109535}, journal-iso = {MECH SYST SIGNAL PR}, journal = {MECHANICAL SYSTEMS AND SIGNAL PROCESSING}, volume = {182}, unique-id = {33167891}, issn = {0888-3270}, abstract = {Efficient and accurate chatter prediction is essential for selection of chatter-free process parame-ters in order to improve machining productivity and surface quality of the workpiece. This paper proposes a five-point Gaussian quadrature-based chatter prediction method of milling processes together with a transition matrix reduction scheme to improve the computational accuracy and efficiency. The five-point Gauss-Legendre quadrature rule is utilized to approximate the equations of motion of milling systems represented in the form of integral equation. By this means, the convergence rate of the chatter prediction method can be improved. Since the transition matrix describing the relation between the states of current and previous tooth or spindle period is used to evaluate chatter stability, its dimension has a significant effect on the computational efficiency. In this paper, it is theoretically proved that the dimension of the transition matrix constructed by numerical integration-based methods can be reduced by half. Based on this, an efficient scheme is firstly proposed to further decrease the computational time. Typical benchmark examples are employed to verify the proposed method. The results demonstrate that the proposed method with the transition matrix reduction scheme is more efficient and accurate than the existing methods. Meanwhile, experimental validation shows the proposed method can predict the milling chatter accurately.}, keywords = {Milling; Chatterprediction; Transitionmatrixreduction; Numericalintegration; Gaussianquadraturerule; Stabilitylobediagram(SLD)}, year = {2023}, eissn = {1096-1216} } @article{MTMT:34265283, title = {Generalized model for dynamics and stability of milling of titanium alloys by integrating process damping, multiple modes and multiple delays}, url = {https://m2.mtmt.hu/api/publication/34265283}, author = {Yang, Yun and Yuan, Jia-Wei and Liu, Hua-Chen and Wan, Min and Zhang, Wei-Hong}, doi = {10.1016/j.jmapro.2023.07.071}, journal-iso = {J MANUFACT PROCES}, journal = {JOURNAL OF MANUFACTURING PROCESSES}, volume = {102}, unique-id = {34265283}, issn = {1526-6125}, abstract = {Machining dynamics modelling and chatter stability prediction are important for milling of titanium alloys to improve machining productivity and surface quality. Since titanium alloys are typically machined at low spindle speeds, process damping plays an important role in dynamics and stability of milling of titanium alloys. What is more, multiple modes and multiple delays, resulting from the complexity of milling systems and processes, significantly affect chatter stability of milling. However, there is a lack of comprehensive dynamical models capable of studying how these three factors influence chatter stability. To address this gap, this paper proposes a generalized dynamic model for milling of titanium alloys considering process damping, multiple modes and multiple delays. A time-domain chatter prediction method related to the generalized dynamic model is proposed by extending the Gaussian quadrature-based method. Experiments are conducted on multi mode cutting systems using both uniform and variable pitch cutters to validate the proposed dynamic model and chatter prediction method. The impacts of multiple modes and multiple delays on chatter stability are investigated considering the presence of process damping. Experimental validation and simulation show that in order to accurately predict chatter stability of milling of titanium alloys at low spindle speed, all dynamic modes should be taken into account whether the modes are well separated or not. Even if the low-frequency modes are much more rigid than the high-frequency modes, low-frequency modes may be dominant in milling of titanium alloys and should be considered in the prediction procedure of chatter stability. In addition, it is observed in both simulations and experiments that variable pitch angles can improve the chatter stability limit in the process damping zone.}, keywords = {Titanium alloys; Stability lobe diagram (SLD); process damping; Multiple modes; Variable pitch cutter; Gaussian quadrature-based method}, year = {2023}, eissn = {2212-4616}, pages = {718-735} } @article{MTMT:34297928, title = {Design of parallel multiple tuned mass dampers for the vibration suppression of a parallel machining robot}, url = {https://m2.mtmt.hu/api/publication/34297928}, author = {Zhang, Jiajun and Xie, Fugui and Ma, Zijian and Liu, Xin-Jun and Zhao, Huichan}, doi = {10.1016/j.ymssp.2023.110506}, journal-iso = {MECH SYST SIGNAL PR}, journal = {MECHANICAL SYSTEMS AND SIGNAL PROCESSING}, volume = {200}, unique-id = {34297928}, issn = {0888-3270}, abstract = {Parallel machining robots have the potentials of high precision and high flexibility. However, their pose-dependent vibration characteristics may cause accuracy problems during machining, which poses a great challenge to the vibration suppression. Multiple tuned mass dampers (MTMDs) are widely used to suppress the vibration, owing to their significant vibration suppressing effect, great robustness, and compact structure. In this paper, a parallel MTMD system is designed to mitigate the forced vibration of a parallel machining robot. The elasto-dynamic model of the parallel robot is established to identify the modes and natural frequencies of the robot, and the results show that the frequency of the resonant mode varies from 91.0 Hz to 128.1 Hz. Based on the structure and natural frequency scope of the robot, the MTMD system is designed to be a parallel configuration in two directions and the impedance model of the MTMD system is built. Considering the pose-dependent dynamics and compact inner space of parallel robots, a multiobjective optimization method for varied vibration characteristics is proposed based on the impedance model. In this method, the suppression amplitude, robustness, and compactness are the main concerns. In the structural design, small-sized polymer material springs and viscous fluid damping inside the mass blocks are used to compose the MTMD system. Therefore, wide-band vibration suppression is realized in narrow spaces. Finally, verification experiments are performed. Modal tests show that the amplitudes of the resonant modes are decreased by 38.8% along the X axis and 40.7% along the Y axis. Machining tests show that a 20%-30% reduction of the vibration in the feed direction, a 40%-50% reduction in the radial direction, a 48%-55% harmonics reduction at the natural frequency are achieved. Precise surface measurements show a 32% reduction in waviness and a 17% reduction in roughness. This study provides a new structural design and optimization method of MTMDs adapted to vibration suppression for parallel machining robots.}, keywords = {Parallel configuration; Vibration suppression; Parallel machining robot; Multiple tuned mass dampers}, year = {2023}, eissn = {1096-1216}, orcid-numbers = {Xie, Fugui/0000-0001-7049-2010} } @article{MTMT:34297917, title = {Investigation of chatter suppression by using rotating composite boring bar CNT-filled based on a modified nonlinear dynamical model}, url = {https://m2.mtmt.hu/api/publication/34297917}, author = {Zhang, Jinfeng and Jia, Junlei and Feng, Chao and Wang, Zhong and Ren, Yongsheng and Zhong, Peisi}, doi = {10.1007/s11071-023-08986-7}, journal-iso = {NONLINEAR DYNAM}, journal = {NONLINEAR DYNAMICS}, unique-id = {34297917}, issn = {0924-090X}, abstract = {Compared with traditional linear models, the nonlinear model of boring can profoundly reveal the physical mechanism and mathematical laws of chatter occurrence, and has more rich scientific connotations. The nonlinear kinematic equations of the composite boring system containing carbon nanomaterials (CNMs) are derived by utilizing the energy method, which is taken to be the entry point for this paper. First of all, the basic mechanical parameters for the composite boring bar CNMs-embedded are derived based on the Halpin-Tsai Model (HTM) and the Rules of Mixture (ROM). From the perspective of continuous distribution, the mathematical expressions of kinetic and potential energy of the rotating boring bar are proposed by introducing the nonlinear strain. The specific and detailed nonlinear dynamic equations of the boring system are obtained using the extended Hamilton's principle by considering the non-conservative virtual work consists of the nonlinear regenerative cutting and the damping force resulting from the viscoelastic and hysteretic damping of composite. Next, the nonlinear equations above are numerically decomposed and simplified using the general Galerkin method combined with modal expansion. The compact nonlinear equations are solved by the Multi-scale method and the primary and super-harmonic resonance solutions are obtained for the forward and backward modes, respectively. Then, the above nonlinear theoretical models are validated with published literature. Finally, the effects of CNMs, carbon fibers, cutting technological parameters on chatter amplitude as well as the unstable zone (curves) are investigated. The conclusions obtained confirm that the nonlinear theoretical model of the boring system proposed in present paper can effectively predict the complex relationships between various parameters within the boring system and provide theoretical guidance for the design of the composite cutter bar.}, keywords = {Internal damping; Nano-carbon material; Critical parameters; Composite boring bar}, year = {2023}, eissn = {1573-269X} } @article{MTMT:33907258, title = {Improving generalisation and accuracy of on-line milling chatter detection via a novel hybrid deep convolutional neural network}, url = {https://m2.mtmt.hu/api/publication/33907258}, author = {Zhang, Pengfei and Gao, Dong and Hong, Dongbo and Lu, Yong and Wu, Qian and Zan, Shusong and Liao, Zhirong}, doi = {10.1016/j.ymssp.2023.110241}, journal-iso = {MECH SYST SIGNAL PR}, journal = {MECHANICAL SYSTEMS AND SIGNAL PROCESSING}, volume = {193}, unique-id = {33907258}, issn = {0888-3270}, abstract = {Unstable chatter seriously reduces the quality of machined workpiece and machining efficiency. In order to improve productivity, on-line chatter detection has attracted much interest in the past decades. Nevertheless, traditional methods are inevitably flawed due to the manually extracted features. Deep learning methods possess outstanding feature learning and classification capabil-ities, but the generalisation and accuracy are severely affected by the labelling and training of data. To address this, this paper proposed a novel hybrid deep convolutional neural network method combining an Inception module and a Squeeze-and-Excitation ResNet block (SR-block), namely ISR-CNN. The Inception module can automatically extract multi-scale features of cutting force signal to enrich the feature map. The SR-block can assign weights to different feature channels, thus suppressing useless feature maps and improving the model accuracy. Meanwhile, the introduction of SR-block also reduces the risk of gradient disappearance and speeds up the training of network. The generalisation and accuracy of the model is guaranteed by combining the two modules without training with transition state data. Milling tests were carried out on a wedge-shaped workpiece using different cutting parameters and tool overhang lengths to verify the accuracy and generalisability of the proposed method. The results showed that the proposed method outperforms other methods by achieving classification accuracy of on the validation and test sets 100% and 97.8%, respectively. In comparison to existing methods, the proposed method can correctly identify each machining state, including the transition states. Furthermore, the proposed method identifies the onset of chatter earlier than other methods, which is beneficial for chatter suppression.}, keywords = {Deep learning; Chatter detection; ResNet; Inception network; Squeeze -and -excitation network}, year = {2023}, eissn = {1096-1216} } @article{MTMT:34242586, title = {Milling Stability Prediction: A New Approach Based on a Composited Newton-Cotes Formula}, url = {https://m2.mtmt.hu/api/publication/34242586}, author = {Zheng, Junqiang and Ren, Pengfei and Zhou, Chaofeng and Du, Xu}, doi = {10.3390/mi14071304}, journal-iso = {MICROMACHINES-BASEL}, journal = {MICROMACHINES}, volume = {14}, unique-id = {34242586}, abstract = {Based on a composited Newton-Cotes formula, this paper proposes a numerical method to predict milling stability considering regenerative chatter and focusing on rate and prediction accuracy. First, the dynamic model of milling motion is expressed as state-space equations considering regenerative chatter, with the tooth passing period divided into a set of time intervals. Second, a composited Newton-Cotes formula is introduced to calculate the transition function map for each time interval. Third, the state transition matrix is constructed based on the above-mentioned transition function, and the prediction stability boundary is determined by the Floquet theory. Finally, simulation analysis and experimental verification are conducted to verify the effectiveness of the proposed method. The simulation results demonstrate that, for the milling model with a single degree of freedom (DOF), the convergence rate and prediction accuracy of the proposed method are higher than those of the comparison method. The experimental results demonstrate that, for the milling model with two DOFs, the machining parameters below the prediction stability boundary can avoid the chatter as much as possible, ensuring the machined surface quality.}, keywords = {dynamic model; Floquet theory; REGENERATIVE CHATTER; Milling stability prediction; composite cotes formula}, year = {2023}, eissn = {2072-666X} } @article{MTMT:34619010, title = {A method to predict chatter stability accurately in milling thin-walled parts by considering force-induced deformation}, url = {https://m2.mtmt.hu/api/publication/34619010}, author = {Zheng, Yawei and Zhao, Zhengcai and Xu, Baode and Yu, Yuan and Xu, Jiuhua}, doi = {10.1016/j.jmapro.2023.10.033}, journal-iso = {J MANUFACT PROCES}, journal = {JOURNAL OF MANUFACTURING PROCESSES}, volume = {106}, unique-id = {34619010}, issn = {1526-6125}, abstract = {Thin-walled parts are susceptible to deformation and chatter in milling due to their low rigidity, which can negatively affect machining quality and efficiency. Deformation induced by cutting force has an impact on chatter stability, making it difficult to predict the stability of the milling system accurately. To address the above issue, this paper presents a systematic study on the force-induced deformation and chatter stability, with a fast method for calculating the deformation and predicting the chatter stability accurately. Firstly, a dynamic model for milling thin-walled part and a finite element model for calculating force-induced deformation were established. The mechanism of the deformation on chatter stability was analyzed. Secondly, a method for quickly calculating the force-induced deformation using a surrogate model of radial basis function neural network was proposed. The model was built using a small amount of finite element simulation data, which can accurately predict the deformation and its distribution. Finally, the chatter stability was predicted by the obtained dynamic parameters and validated by the milling tests. The results indicate that this method can reduce computation time and improve prediction accuracy evidently.}, keywords = {Chatter stability prediction; Chatter stability prediction; Thin -walled parts; Force -induced deformation; Thin -walled parts; Force -induced deformation}, year = {2023}, eissn = {2212-4616}, pages = {552-563} } @article{MTMT:33316654, title = {Bayesian updating of modal parameters for modeling chatter in turning}, url = {https://m2.mtmt.hu/api/publication/33316654}, author = {Ahmadi, Keivan}, doi = {10.1016/j.cirpj.2022.06.006}, journal-iso = {CIRP J MANUF SCI TECHNOL}, journal = {CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY}, volume = {38}, unique-id = {33316654}, issn = {1755-5817}, abstract = {Variations in the mechanics and dynamics of the machining process under operational conditions cause inaccuracies in chatter model predictions. The parameters of chatter models therefore require re-calibration based on experimental observations during machining. This paper presents a new Bayesian method for the in-process calibration of chatter model parameters in turning. The new method comprises two stages. First, we identify the dominant closed-loop poles of the machining system from in-process vibration signals; then, we use those poles in a Bayesian model updating method to determine the probability distributions of the model parameters. Compared to existing methods, which require experimental observations under both stable and unstable conditions, the presented method requires a limited set of vibration measurements during stable conditions only. Moreover, the updated probability distributions are used to establish cred-ibility bounds around the Stability Lobe Diagrams (SLD). An experimental example is presented to de-monstrate the efficiency and effectiveness of the presented method in enhancing the accuracy of chatter predictions in turning. (c) 2022 CIRP.}, keywords = {CHATTER; operational modal analysis; Bayesian model updating}, year = {2022}, eissn = {1755-5817}, pages = {724-736} } @article{MTMT:33316659, title = {A new design of boring bar using TiNi3 alloy to reduce vibration in turning operations}, url = {https://m2.mtmt.hu/api/publication/33316659}, author = {Akdeniz, Eymen and Arslan, Hakan}, doi = {10.1177/09544054221104607}, journal-iso = {P I MECH ENG B-J ENG}, journal = {PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE}, unique-id = {33316659}, issn = {0954-4054}, abstract = {In turning operations, vibration is a significant problem that leads to an imperfect surface, cutting tool damage, and unstable production. Vibration affects not only the workpiece's surface quality, but also the cutting tool life, and ultimately the overall process cost. Since Shape Memory Alloys (SMA) has a very high vibration damping capacity, the effect of using TiNi3 alloy as the turning tool holder material is investigated in this paper. The tool holder vibrations are investigated analytically and numerically in both external and internal turning operations. The analytical study utilizes the Laplace Transformation Method to find the natural frequency and the beam's displacement as a function of time and the longitudinal axis. The numerical study is performed using transient and Modal Analysis using ANSYS software. A comparison of the analytical and numerical results shows that they were very close to each other. The numerical study shows that TiNi3 alloy decreases vibration amplitude and acceleration for external and internal turning operations. It is shown that the use of TiNi3 alloy in the turning cutting tools decrease the vibration acceleration amplitudes by 43.1% and 40.2% for internal and external turning operations, respectively. Additional improvement in the performance of the internal turning cutting tool is achieved by presenting a new model of the boring bar that depends on the integrating of TiNi3 alloy and carbide material. Optimization of five steps is made to obtain the optimal design of the presented model. The new model shows that the optimized boring bar decreases the vibration acceleration by 60.2% compared to the commercial boring bar. Therefore we strongly recommend it for manufacturing turning tool holders.}, keywords = {Turning; Optimization; Analytical model; VIBRATION; Boring bar; TiNi3 alloy}, year = {2022}, eissn = {2041-1975}, orcid-numbers = {Arslan, Hakan/0000-0002-2019-1882} } @article{MTMT:32805795, title = {Improvement of boring operations by means of mode coupling effect}, url = {https://m2.mtmt.hu/api/publication/32805795}, author = {Astarloa, A. and Comak, A. and Mancisidor, I. and Fernandes, M.H. and Munoa, J. and Dombóvári, Zoltán}, doi = {10.1016/j.cirpj.2022.03.008}, journal-iso = {CIRP J MANUF SCI TECHNOL}, journal = {CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY}, volume = {37}, unique-id = {32805795}, issn = {1755-5817}, year = {2022}, eissn = {1755-5817}, pages = {633-644}, orcid-numbers = {Dombóvári, Zoltán/0000-0003-2591-3220} } @article{MTMT:34541198, title = {Lightweight and Robust Chatter Detection Algorithms for Milling}, url = {https://m2.mtmt.hu/api/publication/34541198}, author = {Bahtiyar, Kaan and Sencer, Burak}, journal-iso = {Manufacturing Letters}, journal = {Manufacturing Letters}, volume = {33}, unique-id = {34541198}, issn = {2213-8463}, abstract = {Most machining processes suffer from self-excited chatter vibrations that destroy the work surface and affect machine tool's health. Therefore, accurate and timely detection of chatter vibrations is critical for productivity and longevity of the manufacturing equipment. This paper presents two different chatter detection algorithms for milling process by monitoring power spectrum of the vibration signal measured on the machine. Firstly, a real-time suitable computationally efficient approach is presented, which computes total spectral power of the vibration signal using time-domain variance operator and forced vibration power using moving Fourier transform. Power spectrum of chatter vibration is then evaluated by deducting the forced vibration component from the total signal power. The second method is based on Principal Component Analysis (PCA), which extracts the dominant harmonics of the measured vibration signal. Forced and chatter vibration harmonics are then clustered and labeled to evaluate the forced and chatter vibration powers based on their eigenvectors and eigenvalue magnitudes. For both methods, the power ratio (PR) is used to detect chatter. Once PR exceeds 0.5, chatter starts to dominate whole process, and it is detected. Both algorithms are experimentally tested in machining flexible workpieces. Results show that although both methods perform well on detecting chatter timely, computationally efficient algorithm gives false alarms for flexible workpiece while PCA based algorithm provides more robust chatter detection.}, keywords = {CHATTER; Milling; VIBRATION; Engineering, Manufacturing}, year = {2022}, pages = {388-394} } @article{MTMT:33316631, title = {Lightweight and Robust Chatter Detection Algorithms for Milling}, url = {https://m2.mtmt.hu/api/publication/33316631}, author = {Bahtiyar, Kaan and Sencer, Burak}, journal-iso = {Manufacturing Letters}, journal = {Manufacturing Letters}, volume = {33}, unique-id = {33316631}, issn = {2213-8463}, abstract = {Most machining processes suffer from self-excited chatter vibrations that destroy the work surface and affect machine tool's health. Therefore, accurate and timely detection of chatter vibrations is critical for productivity and longevity of the manufacturing equipment. This paper presents two different chatter detection algorithms for milling process by monitoring power spectrum of the vibration signal measured on the machine. Firstly, a real-time suitable computationally efficient approach is presented, which computes total spectral power of the vibration signal using time-domain variance operator and forced vibration power using moving Fourier transform. Power spectrum of chatter vibration is then evaluated by deducting the forced vibration component from the total signal power. The second method is based on Principal Component Analysis (PCA), which extracts the dominant harmonics of the measured vibration signal. Forced and chatter vibration harmonics are then clustered and labeled to evaluate the forced and chatter vibration powers based on their eigenvectors and eigenvalue magnitudes. For both methods, the power ratio (PR) is used to detect chatter. Once PR exceeds 0.5, chatter starts to dominate whole process, and it is detected. Both algorithms are experimentally tested in machining flexible workpieces. Results show that although both methods perform well on detecting chatter timely, computationally efficient algorithm gives false alarms for flexible workpiece while PCA based algorithm provides more robust chatter detection. (C) 2022 Society of Manufacturing Engineers (SME). Published by Elsevier Ltd. All rights reserved.}, keywords = {CHATTER; Milling; Detection; VIBRATION}, year = {2022}, pages = {388-394} } @article{MTMT:33316662, title = {APPLICATION OF A MULTI TUNED MASS DISC DAMPERS SYSTEM TO A PORTAL MILLING MACHINE}, url = {https://m2.mtmt.hu/api/publication/33316662}, author = {BRECHER, C. H. R. I. S. T. I. A. N. and ZHAO, G. U. I. F. E. N. G. and FEY, M. A. R. C. E. L.}, doi = {10.17973/MMSJ.2022_06_2022048}, journal-iso = {MM Science Journal}, journal = {MM Science Journal}, volume = {2022}, unique-id = {33316662}, issn = {1803-1269}, abstract = {The dynamic performances of the machine tools have decisive influence on the achievable accuracy and productivity of the machining processes. For reducing the unfavourable vibrations of machine tools, a system of multi tuned mass disc dampers (MMD system) is developed in this paper. The simulation model of a portal milling machine is built on its CAD model. Thenceforth, the simulation model is parameterized based on the measured natural frequencies, vibration modes and frequency response functions (FRF) of the portal milling machine. Utilizing the parameterized simulation model, the MMD system is designed, the influence of the tuning errors of the dampers is analysed and the robustness of the MMD system is evaluated. The effectiveness and the robustness of the MMD system is validated through FRF measurements and cutting tests on the portal milling machine.}, keywords = {simulation; Cutting test; tuned mass disc damper; multi-mass dampers; impact hammer test; large scale machine tool}, year = {2022}, eissn = {1805-0476}, pages = {5620-5628} } @article{MTMT:33316677, title = {Relationship between dynamic characteristics of air film of aerostatic spindle and mid-frequency of surface topography}, url = {https://m2.mtmt.hu/api/publication/33316677}, author = {Chen, Dong-Ju and Li, Shu-Pei and Zhang, Xuan and Fan, Jin-Wei}, doi = {10.1007/s40436-022-00391-4}, journal-iso = {ADV MANUF}, journal = {ADVANCES IN MANUFACTURING}, volume = {10}, unique-id = {33316677}, issn = {2095-3127}, abstract = {The dynamic characteristics of the gas film of an aerostatic spindle primary affect workpiece waviness in ultra-precision machining. To improve the machining accuracy of the machine tool and provide a firm theoretical basis for the design of an aerostatic spindle, a simulation model combining transient computational fluid dynamics (CFD) analysis and transient dynamic analysis is established in this study to investigate the dynamic characteristics of the spindle under unstable operating conditions. Based on a large eddy simulation, a three-dimensional flow model of an air film in an aerostatic spindle is established. The simulation results show that the gas flow in the throttle chamber is turbulent, and that complex vortices are formed. Using dynamic grid modeling technology, a CFD numerical model for the unsteady calculation of the spindle is established, and the dynamic characteristics of the gas film are obtained. A transient dynamic simulation model of an aerostatic spindle is established, and the effect of the nonlinear dynamic characteristics of the gas film on the spindle displacement response is investigated. Subsequently, a surface morphology prediction model is established. Results show that film fluctuation significantly affects the dynamic characteristics of the spindle and subsequently affects the generation of surface ripples on the workpiece.}, keywords = {Dynamic characteristics; Surface formation; Aerostatic spindle; Ultra-precision flying cutting}, year = {2022}, eissn = {2195-3597}, pages = {428-442} } @article{MTMT:33316680, title = {Transfer Learning Under Conditional Shift Based on Fuzzy Residual}, url = {https://m2.mtmt.hu/api/publication/33316680}, author = {Chen, Gengxiang and Li, Yingguang and Liu, Xu}, doi = {10.1109/TCYB.2020.2988277}, journal-iso = {IEEE T CYBERNETICS}, journal = {IEEE TRANSACTIONS ON CYBERNETICS}, volume = {52}, unique-id = {33316680}, issn = {2168-2267}, abstract = {Transfer learning has received much attention recently and has been proven to be effective in a wide range of applications, whereas studies on regression problems are still scarce. In this article, we focus on the transfer learning problem for regression under the situations of conditional shift where the source and target domains share the same marginal distribution while having different conditional probability distributions. We propose a new framework called transfer learning based on fuzzy residual (ResTL) which learns the target model by preserving the distribution properties of the source data in a model-agnostic way. First, we formulate the target model by adding fuzzy residual to a model-agnostic source model and reuse the antecedent parameters of the source fuzzy system. Then two methods for bias computation are provided for different considerations, which refer to two ResTL methods called ResTL(LS) and ResTL(RD). Finally, we conduct a series of experiments both on a toy example and several real-world datasets to verify the effectiveness of the proposed method.}, keywords = {fuzzy systems; fuzzy system; aerodynamics; Training data; Computational modeling; Data models; Computer numerical control; Task analysis; Transfer learning; Conditional shift; fuzzy residual}, year = {2022}, eissn = {2168-2275}, pages = {960-970}, orcid-numbers = {Chen, Gengxiang/0000-0003-0595-8923; Li, Yingguang/0000-0003-4425-8073} } @article{MTMT:33167895, title = {Estimating pose-dependent FRF in machining robots using multibody dynamics and Gaussian Process Regression}, url = {https://m2.mtmt.hu/api/publication/33167895}, author = {Chen, Han and Ahmadi, Keivan}, doi = {10.1016/j.rcim.2022.102354}, journal-iso = {ROBOT CIM-INT MANUF}, journal = {ROBOTICS AND COMPUTER-INTEGRATED MANUFACTURING}, volume = {77}, unique-id = {33167895}, issn = {0736-5845}, abstract = {Frequency Response Functions (FRF) of the robot at its TCP are essential for modeling and suppression of industrial robots' vibrations during machining operations. Because the robot's FRF change by posture, measuring the FRF experimentally (e.g. by modal testing) is not efficient, and predictive models are needed to obtain the FRF in arbitrary postures. Multibody dynamics models are efficient in estimating pose-dependent FRF, but they usually include a large number of inertial and joint elastic parameters that must be identified experimentally. Moreover, while the inertial parameters in the model are pose-independent, the joint elastic parameters vary significantly by posture. In this work, we present a new parameter identification method that improves the identifiability of multibody models by systematically imposing constraints according to the robot's rigid-body dynamics as well as its physical and geometrical properties. We then use Gaussian Process Regression (GPR) to model the variation of the joint elastic parameters by posture. This new approach in combining multibody modeling with data-driven modeling (GPR) is more generalizable than purely data-driven methods in predicting pose-dependent FRF because it considers the known physics of the system in predictions. The presented method is used to develop a flexible-joint multibody model for a KUKA KR90 robotic arm with a machining end-effector, and the FRF predicted by the model are compared to the FRF measured by impulse hammer tests to validate their accuracy.}, keywords = {Gaussian Process Regression; robotic machining; Elastic joints}, year = {2022}, eissn = {1879-2537} } @article{MTMT:33316661, title = {Vibration damping capability of electrical discharge machined surfaces: Characteristics, mechanism and application}, url = {https://m2.mtmt.hu/api/publication/33316661}, author = {Coelho, Felipe and Koshy, Philip}, doi = {10.1016/j.ijmachtools.2022.103888}, journal-iso = {INT J MACH TOOL MANU}, journal = {INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE}, volume = {177}, unique-id = {33316661}, issn = {0890-6955}, abstract = {This research explored frictional energy dissipation aspects of electrical discharge machined (EDM) surfaces in the context of passive vibration damping. The effect of discharge current and duration was investigated to characterise the damping capability of these surfaces, and to understand the underlying mechanisms. Topographic analyses indicated the damping ratio to be maximised through an interaction between positive skewness and elevated kurtosis of surface height, which facilitates recurrent microslip and plastic deformation at asperity contact edges. This renders EDM textures to be uniquely disposed to vibration control, as demonstrated by their efficacy in enhancing the dynamic performance of a grooving tool.}, keywords = {CHATTER; Electrical discharge machining (EDM); Frictional energy dissipation; Microslip; Passive vibration damping}, year = {2022}, eissn = {1879-2170} } @article{MTMT:33907268, title = {Chatter suppression for milling of thin-walled workpieces based on active modal control}, url = {https://m2.mtmt.hu/api/publication/33907268}, author = {Du, Jianan and Long, Xinhua}, doi = {10.1016/j.jmapro.2022.10.061}, journal-iso = {J MANUFACT PROCES}, journal = {JOURNAL OF MANUFACTURING PROCESSES}, volume = {84}, unique-id = {33907268}, issn = {1526-6125}, abstract = {Owing to the low stiffness of workpiece, chatter easily occurs in milling of thin-walled structures, which may cause poor surface quality and uncontrolled machining accuracy. For suppressing milling chatter of thin-walled workpieces, this paper presents an active control method with a piezoelectric patch actuator. As a flexible body, thin-walled workpieces have more than one modals participating in milling vibration, and its dynamic charac-teristics vary with tool position. This paper establishes dynamic model of the thin-walled workpiece with a semi -analytical method. Considering three order modals of workpiece, actuator position is optimized and active controller is designed. The varying dynamic characteristics of workpiece are overcome by designing controller with the parameters on the maximum vibration position to stabilize the whole process. Experiments verify the necessity of considering more than one modals of workpiece in active control through various chatter charac-teristics dominant by different modals. With the designed control method, the stable cutting depth improves from 0.2 mm to 1 mm.}, keywords = {ACTIVE CONTROL; milling chatter; modal; Thin -walled workpiece; Piezoelectric patch actuator}, year = {2022}, eissn = {2212-4616}, pages = {1042-1053} } @article{MTMT:33172746, title = {Time delay feedback control for milling chatter suppression by reducing the regenerative effect}, url = {https://m2.mtmt.hu/api/publication/33172746}, author = {Du, Jianan and Liu, Xianbo and Long, Xinhua}, doi = {10.1016/j.jmatprotec.2022.117740}, journal-iso = {J MATER PROCESS TECH}, journal = {JOURNAL OF MATERIALS PROCESSING TECHNOLOGY}, volume = {309}, unique-id = {33172746}, issn = {0924-0136}, abstract = {Chatter often occurs in the milling process and results in poor surface quality, which limits machining efficiency. In order to suppress milling chatter, a time delay feedback control method is proposed and achieved in milling chatter suppression. The controller is designed by solving a Lyapunov function containing time delay and performed in the active control system. Different from traditional real time feedback control methods, this method suppresses milling chatter by reducing the regenerative effect with higher energy efficiency. Simulated andexperimental results indicate the critical depth of milling improves nearly four times with the proposed controller. In addition, the energy cost in the time delay feedback controller is about one-fifth of that in the real time feedback controller. The small actuating force requirement makes active chatter suppression possible in practical manufacture.}, keywords = {Energy cost; ACTIVE CONTROL; milling chatter; Regenerative effect; Time delay feedback}, year = {2022}, eissn = {1873-4774} } @article{MTMT:32952985, title = {Chatter Stability of Serrated Milling Tools in Frequency Domain}, url = {https://m2.mtmt.hu/api/publication/32952985}, author = {Farahani, Nima Dabiri and Altintas, Yusuf}, doi = {10.1115/1.4052007}, journal-iso = {J MANUF SCI E-T ASME}, journal = {JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME}, volume = {144}, unique-id = {32952985}, issn = {1087-1357}, abstract = {Serrated milling tools are widely used for chatter suppression in roughing difficult-to-cut Titanium and Nickel alloys in the aerospace industry. Due to the complexity of chip generation and serration wave geometries ground on the flutes, the chatter stability diagrams are predicted with time marching numerical simulation or semi-discrete time-domain methods, which are computationally too costly to use in practice. This paper presents a frequency domain model of milling dynamics with variable delays caused by the flute serrations. The endmill is divided into discrete cylindrical elements, each having a different radius from the cutter axis. As the cutter rotates and cuts metal, the angular distance between the subsequent tooth varies as a function of serration amplitudes and feedrate; hence, the regenerative delays vary. The angular delays and effective directional factors are averaged for each tooth to form a time-independent but serration-dependent characteristics equation for all discrete cutter elements. The stability of the resulting characteristic equation of the system is solved using Nyquist theory and compared against the experimental results and existing time marching and semi-discrete time-domain solutions. The proposed analytical model predicts the stability charts about 30 times faster than the time-domain models while providing acceptable accuracy.}, keywords = {Modeling and simulation; machining processes; machine tool dynamics}, year = {2022}, eissn = {1528-8935} } @article{MTMT:33316670, title = {A Methodology for Tribo-Mechanical Characterization of Metallic Alloys under Extreme Loading and Temperature Conditions Typical of Metal Cutting Processes}, url = {https://m2.mtmt.hu/api/publication/33316670}, author = {Gregorio, Afonso V. L. and Silva, Tiago E. F. and Reis, Alcino P. and de Jesus, Abilio M. P. and Rosa, Pedro A. R.}, doi = {10.3390/jmmp6020046}, journal-iso = {J MANUF MATER PROC}, journal = {JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING}, volume = {6}, unique-id = {33316670}, abstract = {The present paper proposes a combined tribo-mechanical methodology for assessing friction under conditions representative of metal cutting, without resorting to machining process monitoring. The purpose is to withdraw the size effect's contribution due to tool edge radius to the well-known overestimation of the friction coefficient. Comparative numerical analysis of several tribological tests led us to conclude that the ring compression test is one of the most suitable for reproducing the frictional conditions at the chip-tool interface. Two distinct metallic alloys were selected to demonstrate the application of the proposed methodology (UNS L51120 lead alloy and 18Ni300 maraging steel in conventional and additively manufactured conditions). The results help to better explain the influences of process parameters on the friction coefficient value under high temperature and high strain rate conditions. Results showed a typical increase in the coefficient of friction of up to 20% due to both temperature and strain rate parameters for 18Ni300. The results are of interest because they allow considering potential sources of error in the numerical simulation of metal cutting when the same friction coefficient value is considered for a wide range of cutting parameters.}, keywords = {TEMPERATURE; Orthogonal cutting; Numerical simulation; Friction coefficient; Strain rate; Metal cutting; Flow stress; Ring test; 18Ni300 maraging steel; UNS L51120 lead alloy}, year = {2022}, eissn = {2504-4494} } @article{MTMT:32586956, title = {Regenerative Effects of Orthogonal Chip Dimensions on Turning Stability of Thin-Wall Workpiece-Tool Coupled Dynamics}, url = {https://m2.mtmt.hu/api/publication/32586956}, author = {Guo, Jiajie and Lee, Kok-Meng and Yu, Man and Ma, Haifeng and Xiong, Zhenhua}, doi = {10.1109/TMECH.2021.3135808}, journal-iso = {IEEE-ASME T MECH}, journal = {IEEE-ASME TRANSACTIONS ON MECHATRONICS}, volume = {27}, unique-id = {32586956}, issn = {1083-4435}, abstract = {Machining stability of thin-wall (flexible) components plays an important role in manufacturing efficiency and final product qualities, where machining dynamics are characterized by infinite degrees of freedom distributed in both the time and spatial domains. This article presents a distributed parameter method to model the coupled workpiece-cutting tool (WP-CT) dynamics and investigate the regenerative effects of both depth and width of cut on turning stability. By accounting for the regenerative effects in both radial and axial directions of a flexible disk component, this method relaxes a commonly made assumption that the regenerative chip of the coupled WP/CT dynamics varies in the direction of chip thickness. Formulated using the energy method, the dynamic model that requires only a few dominant modes is developed to construct 3-D stability lobe diagrams in terms of width/depth of cut, rotational speed, and cutting position. The proposed modeling method, which offers a means to identify parameters of a coupled WP-CT system and predict the spatially distributed vibrations and their effects on machining stability, has been analyzed in simulation and validated with experiments.}, keywords = {Distributed parameter model; Stability lobe diagram; Machining dynamics; flexible workpiece (WP); thin-wall component}, year = {2022}, eissn = {1941-014X}, pages = {3601-3612} } @article{MTMT:33316641, title = {The prediction of surface roughness and tool vibration by using metaheuristic-based ANFIS during dry turning of Al alloy (AA6013)}, url = {https://m2.mtmt.hu/api/publication/33316641}, author = {Guvenc, Mehmet Ali and Bilgic, Hasan Huseyin and Cakir, Mustafa and Mistikoglu, Selcuk}, doi = {10.1007/s40430-022-03798-z}, journal-iso = {J BRAZ SOC MECH SCI}, journal = {JOURNAL OF THE BRAZILIAN SOCIETY OF MECHANICAL SCIENCES AND ENGINEERING}, volume = {44}, unique-id = {33316641}, issn = {1678-5878}, abstract = {In this article, the adaptive neuro-based fuzzy inference system (ANFIS) model is developed to estimate the surface roughness (Ra) and tool vibrations (Acc) of AA6013 aluminum alloy during dry turning. Turning experiments were carried out with seven different cutting speeds, five different feed rates and seven different depth of cuts. These three different cutting parameters were tested with each other in different variations. ANFIS model is optimized using the genetic algorithm (GA), particle swarm optimization (PSO) and ant colony optimization. Performance of the developed model is compared with that of multi-linear regression model, which is one of the conventional prediction approaches. At the end of the study, it is revealed that the GA-ANFIS with an R-value of 0.946 is seen as the best model among the proposed approaches in the estimation of Acc. The PSO-ANFIS with an R-value of 0.916 is seen as the best model among the proposed approaches in the estimation of Ra. GA-ANFIS model for Acc prediction and PSO-ANFIS model for Ra prediction are the best approaches among the models discussed in the study. Moreover, the relationship between Acc and Ra values was examined and an empirical model was proposed.}, keywords = {Turning; Surface roughness; Tool vibration; GA-ANFIS; Adaptive neuro-based fuzzy inference system; PSO-ANFIS; ACO-ANFIS; MLRM}, year = {2022}, eissn = {1806-3691} } @article{MTMT:33316681, title = {Grey based multi-objective optimization of machining performance in boring of aluminium alloy 6061 through piezoelectric shunt damping}, url = {https://m2.mtmt.hu/api/publication/33316681}, author = {Hassan, Kamal and Kang, Amardeep Singh and Prakash, Chander and Singh, Gurraj}, doi = {10.1016/j.matpr.2021.07.450}, journal-iso = {MATER TOD PROC}, journal = {MATERIALS TODAY: PROCEEDINGS}, volume = {50}, unique-id = {33316681}, issn = {2214-7853}, abstract = {Chatter instability contributes to the poor texture of the surface, abridged tool life, and productivity. In orthogonal cutting, chatter decreases with an increase in damping which consequently increases stability limits. This work addresses the chatter reduction by employing piezoelectric transducers on the overhang length of a boring bar with a shunt circuit. The stability of the boring process is significantly affected by the function of frequency retort on the cutting edge. Cutting tests are performed by selecting vibration amplitude, average surface roughness as response parameters and machining characteristics are evaluated by piezoelectric shunt dynamic response. It is experimentally concluded that, compared to the no damping condition, mean vibrational amplitude and surface roughness decreases considerably using piezoelectric damping. Grey relational methodology has been utilized for multi-attribute decision making for depicting the optimal internal turning parameters. (c) 2021 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the 2nd International Conference on Functional Material, Manufacturing and Performances.}, keywords = {CHATTER; Piezoelectric transducers; S; surface texture; Grey relational grade; N ratio}, year = {2022}, pages = {1043-1047}, orcid-numbers = {Hassan, Kamal/0000-0002-2256-5999; Kang, Amardeep Singh/0000-0002-6203-5220; Prakash, Chander/0000-0003-0856-9712} } @article{MTMT:33097006, title = {A review on dynamics in micro-milling}, url = {https://m2.mtmt.hu/api/publication/33097006}, author = {Heitz, Thomas and He, Ning and Chen, Ni and Zhao, Guolong and Li, Liang}, doi = {10.1007/s00170-022-10014-8}, journal-iso = {INT J ADV MANUFACT TECHNOL}, journal = {INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY}, unique-id = {33097006}, issn = {0268-3768}, year = {2022}, eissn = {1433-3015}, orcid-numbers = {He, Ning/0000-0003-2231-7482} } @article{MTMT:33316678, title = {AN IMPACT OF THE STEEL-CONCRETE COMPOSITE SUPPORTING STRUCTURE ON THE DYNAMIC PARAMETERS OF THE MACHINING CENTER}, url = {https://m2.mtmt.hu/api/publication/33316678}, author = {Hermansky, Dominik and Marek, Jiri}, doi = {10.17973/MMSJ.2022_03_2020017}, journal-iso = {MM Science Journal}, journal = {MM Science Journal}, volume = {2022}, unique-id = {33316678}, issn = {1803-1269}, abstract = {A self-excited vibration, called "chatter", is a main limiting factor in chip-forming metal machining. The reduction of machining productivity, worsened machined surface quality and the reduction of lifetime of the machine tool parts, particularly the cutting tool itself, occur as a result of the chatter. There are more ways to suppress this undesired effect of machining. The most common and simplest variant is the structural modification of the supporting parts of the machine in order to increase the dynamic stiffness and damping.In most cases, manufacturers of the machining centers use traditional metallic materials (steel, cast iron) for construction of the machine supporting system. However, these materials have some limitations. In order to improve the dynamic parameters of the machine during machining process it is appropriate to combine these materials with others to create hybrid, composite structures.Authors of this article have performed the real experiment in order to test the real dynamic properties of the vertical multitasking machining center with the turning operation prevailing. The individual segments of the supporting structure are made of the composite material - a combination of a steel welded structure filled with high-strength cement concrete.}, keywords = {CHATTER; Machine tool; steel-concrete composite}, year = {2022}, eissn = {1805-0476}, pages = {5571-5574} } @article{MTMT:33316651, title = {Research on Milling Characteristics of Titanium Alloy TC4 with Variable Helical End Milling Cutter}, url = {https://m2.mtmt.hu/api/publication/33316651}, author = {Hu, Xiangming and Qiao, Hanying and Yang, Mingyu and Zhang, Yaoman}, doi = {10.3390/machines10070537}, journal-iso = {MACHINES}, journal = {MACHINES}, volume = {10}, unique-id = {33316651}, abstract = {The application of variable helical end mills to the milling of titanium alloys can suppress the regeneration effect during the machining process and ensure the stability of milling. However, due to their special geometry, their milling characteristics are also different. In this paper, the process of milling titanium alloy with a variable helix end mill is taken as the research object, and the milling force, milling stability and machining effect during the machining process are deeply studied. Firstly, the feed per tooth and cutting thickness model of the variable helical end mill were established, the milling force prediction model of the variable helical end mill was deduced, and the instantaneous milling force and its variation law were obtained by solution. Secondly, the finite element analysis model of the variable helix end mill for machining titanium alloy was established, and the influence of the variable helix angle structure on the milling force was obtained. Then, the dynamic equation of milling with a variable helix end mill was established, the stability lobe diagram of variable helix milling is was and drawn, and the influence of variable helix angle on milling stability was analyzed. Lastly, a variable helix end mill milling experiment was designed to verify the accuracy of the theoretical model and finite element simulation; the influence of the variable helix angle structure on the surface roughness was analyzed, and the influence of machining parameters on the milling force when using a variable helix end mill was investigated.}, keywords = {Simulation analysis; experimental research; Milling force model; variable helical end milling cutter}, year = {2022}, eissn = {2075-1702} } @article{MTMT:32712472, title = {Alternative experimental methods for machine tool dynamics identification: A review}, url = {https://m2.mtmt.hu/api/publication/32712472}, author = {Iglesias, A. and Taner, Tunç L. and Özsahin, O. and Franco, O. and Munoa, J. and Budak, E.}, doi = {10.1016/j.ymssp.2022.108837}, journal-iso = {MECH SYST SIGNAL PR}, journal = {MECHANICAL SYSTEMS AND SIGNAL PROCESSING}, volume = {170}, unique-id = {32712472}, issn = {0888-3270}, year = {2022}, eissn = {1096-1216} } @article{MTMT:33316689, title = {Improved Vibration Suppression Modeling for Reinforcement Clamping by Eco-friendly Magnetorheological Fluid During Milling of Annular Thin-Walled Workpiece}, url = {https://m2.mtmt.hu/api/publication/33316689}, author = {Jiang, Xiaohui and Wu, Kun and Zhang, Yong and He, Shirong}, doi = {10.1007/s40684-021-00409-5}, journal-iso = {INT J PR ENG MAN-GT}, journal = {INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING-GREEN TECHNOLOGY}, volume = {9}, unique-id = {33316689}, issn = {2288-6206}, abstract = {Milling vibration will greatly affect the milling accuracy and surface quality of thin-walled workpiece. Considering that the characteristics of instant curing high-efficiently under the action of magnetic field and can be recycled without wasted of magnetorheological fluid (MRF), a MRF composite clamping to suppress milling vibration is proposed in this paper. Based on the fluid-solid coupling dynamics theory, the dynamics modal of the MRF clamping is established. On this basis, considering the influences of the filling volume of MRF to processing vibration, the suppression effect of MRF on milling vibration is analyzed in time domain and frequency domain, respectively. A series of simulations and experiments are carried out on typical annular thin-walled workpiece, the result shows that the maximum increase of natural frequency of thin-walled workpiece is 53.1% while filling with MRF, and Ra, Rz, Rq decreased by 36.1%, 14.8% and 16.7%, respectively. The consequence verified the reliability and effectiveness of the proposed method in the whole milling process.}, keywords = {Vibration suppression; fluid-solid coupling; Eco-friendly MRF}, year = {2022}, eissn = {2198-0810}, pages = {1511-1526} } @article{MTMT:33528212, title = {Adjusting the Stiffness of Supports during Milling of a Large-Size Workpiece Using the Salp Swarm Algorithm}, url = {https://m2.mtmt.hu/api/publication/33528212}, author = {Kalinski, Krzysztof J. and Galewski, Marek A. and Stawicka-Morawska, Natalia and Mazur, Michal and Parus, Arkadiusz}, doi = {10.3390/s22145099}, journal-iso = {SENSORS-BASEL}, journal = {SENSORS}, volume = {22}, unique-id = {33528212}, abstract = {This paper concerns the problem of vibration reduction during milling. For this purpose, it is proposed that the standard supports of the workpiece be replaced with adjustable stiffness supports. This affects the modal parameters of the whole system, i.e., object and its supports, which is essential from the point of view of the relative tool-workpiece vibrations. To reduce the vibration level during milling, it is necessary to appropriately set the support stiffness coefficients, which are obtained from numerous milling process simulations. The simulations utilize the model of the workpiece with adjustable supports in the convention of a Finite Element Model (FEM) and a dynamic model of the milling process. The FEM parameters are tuned based on modal tests of the actual workpiece. For assessing simulation results, the proper indicator of vibration level must be selected, which is also discussed in the paper. However, simulating the milling process is time consuming and the total number of simulations needed to search the entire available range of support stiffness coefficients is large. To overcome this issue, the artificial intelligence salp swarm algorithm is used. Finally, for the best combination of stiffness coefficients, the vibration reduction is obtained and a significant reduction in search time for determining the support settings makes the approach proposed in the paper attractive from the point of view of practical applications.}, keywords = {Salp swarm algorithm; large-size workpiece machining; milling vibrations; stiffness adjustment}, year = {2022}, eissn = {1424-8220}, orcid-numbers = {Stawicka-Morawska, Natalia/0000-0002-6565-1977; Parus, Arkadiusz/0000-0001-7254-6051} } @article{MTMT:33316649, title = {Mechanism to suppress regenerative chatter vibration due to the effect of air-cutting and multiple regeneration during low frequency vibration cutting}, url = {https://m2.mtmt.hu/api/publication/33316649}, author = {Kamada, Yo and Kitakaze, Ayako and Sannomiya, Kazuhiko and Nakaya, Takaichi and Sasahara, Hiroyuki}, doi = {10.1016/j.precisioneng.2022.07.002}, journal-iso = {PRECIS ENG}, journal = {PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY}, volume = {78}, unique-id = {33316649}, issn = {0141-6359}, abstract = {Recently, the application of low frequency vibration has been attempted in the turning process. The tool is vibrated in the feed direction by numerical control to break up long continuous chips that adversely affect the surface quality and tool wear, etc., by generating a duration of cutting edge leaving workpiece. In order to achieve higher machining efficiency in vibration cutting, however, it is necessary to focus on chatter stability. When chattering occurs, a higher frequency chatter vibration is superimposed on the low-frequency tool vibration caused by the feed motion of the servo drive. However, the chatter amplitude decreases due to system damping, because the cutting force does not act in the air-cutting section of vibration cutting. In addition, tool displacement is regenerated not only before one spindle rotation, but also before two or more rotations in vibration cutting. Therefore, the application of low frequency vibration has an important influence on the chatter stability. The purpose of this study is to reveal the detailed effects of vibration conditions on the stability limit, and identify the vibration conditions that achieve high chatter stability. We consider the effect of the air-cutting and multi-rotation delayed regeneration described above, in which chatter displacement occurring more than two spindle rotations before is regenerated, and analyze regenerative chatter vibration during vibration cutting in the frequency domain. In this study, the phase difference phi of tool motion in vibration cutting is focused as an important vibration condition parameter that affects the stability limit. In the conventional condition (phi = pi), the air-cutting ratio is limited to a relatively low value, and only the dynamic displacements before one and two spindle revolutions are regenerated. On the other hand, setting phi appropriately under the condition phi =/ pi, the air-cutting ratio is increased. Furthermore, the dynamic displacement is regenerated not only before one and two spindle rotations but also before three or more spindle rotations. These results indicate that proper setting of the phase difference phi is effective in suppressing regenerative chatter vibration due to the effects of both the aircutting phenomenon and multi-rotation delay. Finally, cutting experiments show that the phase difference phi specified by the analysis was effective in suppressing chatter vibration. In summary, the application of low frequency vibration with an appropriately set phase difference phi is an effective strategy for suppressing chatter vibration without reducing the material removal rate in the turning process.}, keywords = {Turning; CHATTER; Low frequency vibration; Multiple regeneration; Vibration cutting; Air -cutting}, year = {2022}, eissn = {1873-2372}, pages = {1-18} } @inproceedings{MTMT:33316637, title = {Sensitivity Function Shaping Method for Non-collocated Active Damping System in Ram-type Milling Machine}, url = {https://m2.mtmt.hu/api/publication/33316637}, author = {Kim, Eun Kyu and Jung, Jae Woo and Jung, Sang Won and Kwon, Yoon Sik and Kang, Bo Min and Lee, Chang Ho and Sim, Kwangseop and Jo, Ok Hyun and Yoon, Jun Young}, booktitle = {2022 IEEE/ASME International Conference on Advanced Intelligent Mechatronics (AIM)}, doi = {10.1109/AIM52237.2022.9863258}, unique-id = {33316637}, abstract = {In this paper, we present the sensitivity function shaping method and its experimental validations for the non-collocated active damping system in a ram-type milling machine. While the non-collocated configuration is often required for the practical reasons in the application of the active damper to the machine structure, such configuration can be challenging to obtain the high-gain control under stable conditions. We analyze the frequency response of the non-collocated active damping system where the opposite-phase-mode dynamics limit the achievable control gain. Utilizing the understanding on the non-collocated plant, we shape the sensitivity function to effectively reduce the closed-loop compliance of the dominant mode dynamics under varying ram postures. We experimentally validate the resultant active damping performance, where the peak compliance of the dominant mode is reduced by a maximum of 61 %. The chatter suppression performance due to the enhancement in the dynamic stiffness is also experimentally validated in rough-machining tests using our active damper and the proposed control method.}, year = {2022}, pages = {415-420} } @article{MTMT:32809396, title = {Bifurcations analysis in implicit maps through the dynamics of cumulated surface errors in milling}, url = {https://m2.mtmt.hu/api/publication/32809396}, author = {Kiss, Ádám and Bachrathy, Dániel}, doi = {10.1007/s11071-022-07486-4}, journal-iso = {NONLINEAR DYNAM}, journal = {NONLINEAR DYNAMICS}, volume = {109}, unique-id = {32809396}, issn = {0924-090X}, year = {2022}, eissn = {1573-269X}, pages = {779-792}, orcid-numbers = {Kiss, Ádám/0000-0002-7074-4553; Bachrathy, Dániel/0000-0003-1491-1852} } @article{MTMT:32705211, title = {In-process impulse response of milling to identify stability properties by signal processing}, url = {https://m2.mtmt.hu/api/publication/32705211}, author = {Kiss, Ádám and Hajdu, Dávid and Bachrathy, Dániel and Stépán, Gábor and Dombóvári, Zoltán}, doi = {10.1016/j.jsv.2022.116849}, journal-iso = {J SOUND VIB}, journal = {JOURNAL OF SOUND AND VIBRATION}, volume = {527}, unique-id = {32705211}, issn = {0022-460X}, year = {2022}, eissn = {1095-8568}, orcid-numbers = {Kiss, Ádám/0000-0002-7074-4553; Hajdu, Dávid/0000-0003-0692-2906; Bachrathy, Dániel/0000-0003-1491-1852; Stépán, Gábor/0000-0003-0309-2409; Dombóvári, Zoltán/0000-0003-2591-3220} } @article{MTMT:33316658, title = {Vibration analysis during AZ31 magnesium alloy milling with the use of different toolholder}, url = {https://m2.mtmt.hu/api/publication/33316658}, author = {Korpysa, Jaroslaw and Zagorski, Ireneusz}, doi = {10.17531/ein.2022.3.10}, journal-iso = {MAINTEN RELIAB}, journal = {EKSPLOATACJA I NIEZAWODNOSC-MAINTENANCE AND RELIABILITY}, volume = {24}, unique-id = {33316658}, issn = {1507-2711}, abstract = {Machining vibrations are an important issue as they occur in all types of machining processes. Due to its negative impact on machining results, this phenomenon is undesirable, and so there have been continuous efforts to find solutions that will minimise it, and thus improve the stability and safety of the machining process. The paper attempts to determine the impact of toolholder type and cutting condition on the vibrations generated while milling an AZ31 magnesium alloy. The tests were performed using the three most common types of toolholders: ER, Shrink Fit and hydraulic. The vibration displacement and acceleration signals were analysed based on parameters such as Peak-to-Peak, Peak, and Root Mean Square. Composite Multiscale Entropy was also applied to check the stability of cutting processes and define the level of signal irregularity. To determine the frequencies of vibrations and to detect chatter vibrations Fast Fourier Transform was performed. This provides information on the stability and enables vibrations to be minimized by avoiding unfavourable cutting conditions.}, keywords = {STABILITY; MAGNESIUM ALLOY; Milling; VIBRATION}, year = {2022}, eissn = {1507-2711}, pages = {489-501}, orcid-numbers = {Korpysa, Jaroslaw/0000-0002-5833-7074} } @article{MTMT:33316647, title = {Review of AI-based methods for chatter detection in machining based on bibliometric analysis}, url = {https://m2.mtmt.hu/api/publication/33316647}, author = {Kounta, Cheick Abdoul Kadir A. and Arnaud, Lionel and Kamsu-Foguem, Bernard and Tangara, Fana}, doi = {10.1007/s00170-022-10059-9}, journal-iso = {INT J ADV MANUFACT TECHNOL}, journal = {INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY}, volume = {122}, unique-id = {33316647}, issn = {0268-3768}, abstract = {To improve the finish and efficiency of machining processes, researchers set out to develop techniques to detect, suppress, or avoid vibration chatter. This work involves tracing chatter detection techniques, from time-frequency signal processing methods (FFT, HHT, STFT, etc.), decomposition (WPD, EMD, VMD, etc.) to the combination with machine learning or deep learning models. A cartographic analysis was carried out to discover the limits of these different techniques and to propose possible solutions in perspective to detect chattering in the machining processes. The fact that human expert detects chatter using simple spectrograms is confronted with the variety of signal processing methods used in the literature and lead to possible optimal detecting techniques. For this purpose, the bibliometric tool R-Tool was used to facilitate a bibliometric analysis using specific means for quantitative bibliometric research and visualization. Data were collected from the Web of Science (WoS 2022) using particular queries on chatter detection. Most documents collected detect chatter with either transformation or decomposition techniques.}, keywords = {bibliometrics; machine learning; Signal processing; time-frequency analysis; Deep learning; Chatter detection}, year = {2022}, eissn = {1433-3015}, pages = {2161-2186} } @article{MTMT:32772693, title = {Milling Processes With Active Damping: Modeling and Stability}, url = {https://m2.mtmt.hu/api/publication/32772693}, author = {Lehotzky, Dávid and Mancisidor, Iker and Munoa, Jokin and Dombóvári, Zoltán}, doi = {10.1115/1.4052723}, journal-iso = {J COMPUT NONLIN DYN}, journal = {JOURNAL OF COMPUTATIONAL AND NONLINEAR DYNAMICS}, volume = {17}, unique-id = {32772693}, issn = {1555-1415}, abstract = {Active dampers are on the verge of appearing in commercial machines as devices that assist the avoidance of machine tool chatter. The adjustment of control parameters in these devices is mostly guided by models that do not consider the dynamics within the control loop of active damper. Therefore, these models neglect the dynamics of actuation, measurement, and filtering, which can result in inaccurate stability predictions that hinder the efficient tuning of active dampers. To formulate a more realistic model for milling processes assisted by active damping, this paper derives a novel mathematical model that takes into account the internal dynamics of the actuator, measuring device, and discrete filtering. This study shows that accurate stability prediction requires the incorporation of actuator and filter dynamics into the model, especially at high spindle speeds and large feedback gains.}, keywords = {SYSTEMS; PREDICTION; DELAY; Vibration control; Engineering, Mechanical; Chatter suppression; Turning operations}, year = {2022}, eissn = {1555-1423}, orcid-numbers = {Lehotzky, Dávid/0000-0002-4680-8342; Dombóvári, Zoltán/0000-0003-2591-3220} } @article{MTMT:33316672, title = {Displacement difference feedback control of chatter in milling processes}, url = {https://m2.mtmt.hu/api/publication/33316672}, author = {Li, Denghui and Cao, Hongrui and Chen, Xuefeng}, doi = {10.1007/s00170-022-09128-w}, journal-iso = {INT J ADV MANUFACT TECHNOL}, journal = {INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY}, volume = {120}, unique-id = {33316672}, issn = {0268-3768}, abstract = {Chatter is an unfavorable phenomenon that commonly occurs in the machining process, which results in various problems such as poorly finished surfaces, short tool life, and low machining efficiency. Thus, based on the intelligent manufacturing paradigm, an active chatter control strategy is proposed in this work. Different from the commonly used control methods, which strive to reduce the whole vibration (i.e., stable and chatter vibrations) during the machining process, the proposed strategy focuses on suppressing the chatter component by feeding back the displacement difference of the spindle-tool system at the current time and one tooth passing period before. On the basis of the proposed chatter control concept, a piezoelectric actuator-based active chatter control intelligent spindle-tool system as well as a proportional-differential (PD) controller and a fuzzy controller are designed to perform numerical simulations and milling experiments with different cutting parameters. The results prove that the developed strategies not only successfully control chatter and increase the maximum material removal rate (MRR) but also significantly decrease the required voltage of the actuator, which is conducive to saving control energy.}, keywords = {fuzzy control; PD control; ACTIVE CONTROL; milling chatter; Displacement difference feedback}, year = {2022}, eissn = {1433-3015}, pages = {6053-6066} } @article{MTMT:32942597, title = {Chatter Suppression during Milling of Ti-6Al-4V Based on Variable Pitch Tool and Process Damping Effect}, url = {https://m2.mtmt.hu/api/publication/32942597}, author = {Li, Mengyu and Zhao, Wei and Li, Liang and He, Ning and Jamil, Muhammad}, doi = {10.3390/machines10040222}, journal-iso = {MACHINES}, journal = {MACHINES}, volume = {10}, unique-id = {32942597}, abstract = {Regenerative chatter is a major limitation in the milling of Ti-6Al-4V, resulting in undesirable surface and reducing cutting efficiency. It is well-acknowledged that variable pitch cutter and the process damping effect are effective methods to suppress chatter, and that these two methods are compatible. In this paper, a novel anti-vibration milling tool with combined variable pitch (pitch angles of 85 degrees-95 degrees-85 degrees-95 degrees) and wear edges (60 mu m on the flank face), which helps to increase the process damping effect, is presented. The milling model of variable pitch tool considering process damping effect is developed and the dynamic milling stability is analyzed by using the semi-discretization method. To modify time delay, an analytical formula for optimal tuning variable pitch angles is presented. The effectiveness of the proposed anti-vibration tool is verified by stability diagrams and milling experiments. Industrial experimental results show that compared with the common regular pitch tool and onefold variable pitch tool, when the proposed anti-vibration tool is used, the stable axial depth of cut increases by 97.4% and 26.2%, respectively.}, keywords = {TI-6AL-4V; Milling stability; process damping; variable pitch tool}, year = {2022}, eissn = {2075-1702}, orcid-numbers = {Jamil, Muhammad/0000-0002-7224-769X} } @article{MTMT:32942623, title = {Investigation of variable pitch tool design for chatter suppression in milling of Ti-6Al-4 V: a comparison of simulation and experimental results}, url = {https://m2.mtmt.hu/api/publication/32942623}, author = {Li, Mengyu and Zhao, Wei and Li, Liang and He, Ning}, doi = {10.1007/s00170-022-09481-w}, journal-iso = {INT J ADV MANUFACT TECHNOL}, journal = {INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY}, unique-id = {32942623}, issn = {0268-3768}, abstract = {Regenerative chatter is a major limitation in the milling of Ti-6Al-4 V causing poor surface quality and machining efficiency. As Ti-6Al-4 V is difficult to cut materials, identification of deep stable pockets using stability diagrams and spindle speed variation is not effective due to the high spindle speed zones. An effective way for improving the milling stability is the application of variable pitch tools. With properly designed unequal pitch angles, the destabilizing regenerative is perturbed to suppress chatter. This research aims to present a simple and effective tuning method to optimize design variable pitch angles. The Routh-criterion method is used to analyze the delay differential equation (DDE), and the results indicated that additional damping and stiffness introduced by time delay are two key factors that make the machining system unstable. To modify time delay and to minimize the additional damping and stiffness, a tuning method is built up to determine appropriate pitch angles. Considering the tool manual's recommend cutting conditions, the typical variable pitch milling tools are designed, manufactured, and applied in the milling of Ti-6Al-4 V to evaluate their effectiveness. This research findings have indicated that the milling tool having pitch angles of 85-95-85-95 degrees showed the process stability with a 60% increase in axial depth of cut.}, keywords = {Milling stability; variable pitch tool; Routh-criterion}, year = {2022}, eissn = {1433-3015} } @article{MTMT:33316628, title = {Study on the process damping in milling of thin-walled Ti-6Al-4V workpiece: Modeling, analysis, and prediction}, url = {https://m2.mtmt.hu/api/publication/33316628}, author = {Li, Mengyu and Zhao, Wei and Li, Liang and He, Ning}, doi = {10.1177/09544054221135661}, journal-iso = {P I MECH ENG B-J ENG}, journal = {PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE}, unique-id = {33316628}, issn = {0954-4054}, abstract = {Due to limited stiffness and wall thickness, chatter usually occurs in the milling of thin-walled components, which reduces the surface quality and machining productivity. It is well acknowledged that process damping, which results from the interference between the flank face and the machined surface, can improve the chatter stability. This paper analyzes the influence of process damping on the milling system of thin-walled Ti-6Al-4V alloy based on the Nyquist criterion and the Routh criterion. Meanwhile, a detailed and improved calculation model of the interference area is presented to promote the prediction accuracy of process damping. The comparison of computational results and experimental findings verifies the accuracy of the proposed model. The decrease of spindle speed increases the interference area as well as the total damping of the milling system. When the spindle speed is 1000 rpm, the ultimate stable axial depth of cut increases from 1.2 mm to 2.7 mm by utilizing the special designed end mills based on the presented model.}, keywords = {Milling stability; process damping; thin-walled Ti-6Al-4V}, year = {2022}, eissn = {2041-1975} } @article{MTMT:33316635, title = {Prediction, detection, and suppression of regenerative chatter in milling}, url = {https://m2.mtmt.hu/api/publication/33316635}, author = {Liu, Bo and Liu, Changfu and Yu, Xinli and Zhou, Yang and Wang, Daohai}, doi = {10.1177/16878132221129746}, journal-iso = {ADV MECH ENG}, journal = {ADVANCES IN MECHANICAL ENGINEERING}, volume = {14}, unique-id = {33316635}, issn = {1687-8132}, abstract = {In metal cutting processing, especially in the processing of low-rigidity workpieces, chatter is a key factor affecting many aspects such as surface quality, processing efficiency and tool life. The academic research on chatter mainly focuses on three directions: chatter prediction, real-time detecting, and chatter suppression. With the continuous development of machining toward intelligence, the hot spots and trends of chatter research are also constantly changing. Therefore, an in-depth and systematic summary of the current situation of chatter research is urgently needed. On this basis, it is of great significance to realize the prediction of the hot spots and trends of chatter research. This article summarizes the research status from three aspects of chatter prediction, detecting and suppression, and points out the advantages and limitations of current chatter research. After in-depth discussion, this article also looks forward to the trend of chatter research. The hot spots of chatter research will focus on the following points: (1) Chatter research methods and means based on data-driven. (2) Integrated data collection, processing and decision-making methods. (3) Chatter detecting unit and chatter suppression unit are integrated in the smart spindle. (4) The chatter mechanism and detecting research of robot milling.}, keywords = {Chatter suppression; chatter prediction; Data driven; Processing chatter; real-time detecting}, year = {2022}, eissn = {1687-8140} }