Autonomous calculation of stability lobe diagrams, based on sensory structural compo-nents of a milling center

• Applicant: Professor Dr.-Ing. Berend Denkena
• Subject Area: Metal-Cutting and Abrasive Manufacturing Engineering
• Term: from 2019 to 2023
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 416001186

Chatter vibrations result in higher of tool- and machine loads as well as the manufacturing of reject parts. Hence, process parameters are currently being reduced in order to avoid chatter vibrations or suitable sets of parameters must be determined experimentally. However, this approach results in a reduction of productivity or a high effort in the production planning respectively. Therefore, the goal of this research project is the investigation of a system for autonomous calculation of stability lobe diagrams. First, the coefficients of a cutting force model are calculated based on the quasistatic process force. With the cutting force model, it is possible to calculate dynamic cutting forces. With the calculated dynamic cutting forces as input and the cutting forces, measured with the sensory structure components, as output it is possible to determine the dynamic properties of the tool/tool-holder/machine combination. Based on the cutting force model and the determined system model it is possible to calculate a stability lobe diagram in a first approximation. As soon as process data from different cutting conditions are available, an optimization-algorithm is to be used to reduce modelling errors in the cutting force model and the system model.

• DFG Programme: Research Grants