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Procedia CIRP 77 (2018) 106–109
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8th CIRP Conference on High Performance Cutting (HPC 2018)

An analytical method in modeling

28th CIRP of milling
Design Conference, process
May 2018, damping considering
Nantes, France
cutting edge radius
A new methodology to analyze the functional and physical architecture of
existing products forChang
an assembly oriented
Cao, Xiao-Ming Zhang*product family identification
, Han Ding
School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China
Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat
* Corresponding author. Tel.: +86-2787559842; fax: +86-2787559416. E-mail address: cheungxm@hust.edu.cn

École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France

Abstract
* Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: paul.stief@ensam.eu

Process damping generated between the clearance face of the tool and wavy finish workpiece surface has a strong effect on cutting
dynamics and stability. However, it has been mostly ignored in chatter analysis as there is hardly practical model for estimation of it,
particularly for honed tool which equips arc cutting edge and performs significant process damping effect. The challenge of process damping
Abstract
modeling for cutting with honed tools lies mainly on the computation of the volume of the extruded material under the tool. In this study, based
Inontoday’s
the assumption
business of small amplitude
environment, vibrations,
the trend towardsanmore
analytical
productmodel with
variety high
and computational
customization efficiencyDue
is unbroken. is presented to compute the
to this development, theextruded
need of
volume
agile and inreconfigurable
cutting with production
honed tools.systems
Based emerged
on this model,
to copewewith
derive the equivalent
various products and process damping
product coefficient
families. To designanalytically
and optimizeby production
the energy
dissipation
systems principle
as well as to and thenthe
choose construct
optimalthe stability
product lobes by
matches, Full-Discretization
product Method.
analysis methods are The predicted
needed. cutting
Indeed, most stability is verified
of the known by previous
methods aim to
researchers’ experiments and the existing process damping model. The results demonstrate that the proposed analytical method
analyze a product or one product family on the physical level. Different product families, however, may differ largely in terms of the number and is applicable to
deal with the problem of process damping for honed tool in milling operation.
nature of components. This fact impedes an efficient comparison and choice of appropriate product family combinations for the production
© 2018AThe
system. new Authors. Published
methodology by Elsevier
is proposed Ltd. This
to analyze is an open access article under the CC BY-NC-ND license
© 2018 The Authors. Published by Elsevier
(http://creativecommons.org/licenses/by-nc-nd/3.0/) Ltd. existing products in view of their functional and physical architecture. The aim is to cluster
these products in new assembly oriented product families
This is an open access article under the CC BY-NC-ND license for the optimization of existing assembly lines and the creation of future reconfigurable
(https://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer-review
assembly underBased
responsibility of Flow
the International Scientificstructure
Committee of products
the 8th CIRP Conference on Highsubassemblies
Performance Cutting (HPC and
Selectionsystems.
and peer-review on under
Datum Chain, the
responsibility physical
of the of the
International Scientific is analyzed.
Committee Functional
of the 8th CIRP Conference are identified,
on High Performance
2018).
a Cutting
functional
(HPC analysis
2018). is performed. Moreover, a hybrid functional and physical architecture graph (HyFPAG) is the output which depicts the
similarity between product families by providing design support to both, production system planners and product designers. An illustrative
Keywords:
example of cutting stability;ismilling;
a nail-clipper used toprocess damping;
explain the proposed methodology. An industrial case study on two product families of steering columns of
thyssenkrupp Presta France is then carried out to give a first industrial evaluation of the proposed approach.
© 2017 The Authors. Published by Elsevier B.V.
1. Introduction stability limits at low and high speeds respectively.
Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018.
Alternative experimental method [3] was presented to identify
Process damping plays a crucial role resulting
Keywords: Assembly; Design method; Family identification into higher the process damping coefficients through inverse stability
chatter stability limit at low cutting speeds, which is in analysis using the experimentally identified stability limits. In
accordance with the phenomenon in actual cutting tests. As a addition, Ahmadi and Altintas [4] proposed a new method of
result, the machining efficiency of some hard-to-machine output-only modal analysis in predicting the process damping
1.aerospace
Introduction
materials, which can’t be machined at high cutting of the product
coefficient by range and characteristics
estimating the vibration manufactured
signals measured and/or in
speeds due to excessive tool wear, can be greatly promoted. assembled
chatter freeinorthogonal
this system. In thistests.
cutting context, the main
Recently, Minchallenge
Wan et al. in
OnDue to the
the other hand,fast development
the accuracy in the cutting
of the predicted domainforce of modelling
[5] presented andaanalysis is now
generalized methodnot only to cope
to identify thewith single
ploughing
communication
can be improved and whenan ongoing trend of
considering the digitization
component and of products, a limited which
force coefficient productisrange or existing
suitable for both product families,
of static and
digitalization,
ploughing force manufacturing
caused by processenterprises are facing
damping. important
In general, it is but also tocuts
dynamic be ableby to analyze
only usingand thetostatic
compare products
milling forces.to define
Using
challenges
necessary to in consider
today’s market
the effect environments:
of process a dampingcontinuing in new productapproaches,
analytical families. It Wucan be[6]observed
assumedthat thatclassical existing
the ploughing
tendency
machining towards
process.reduction of product development times and product families
forces were are regrouped
linearly in function
proportional to the of clients
volumeor of features.
work
shortened product lifecycles.
Both experimental and In addition,approaches
analytical there is an increasing
had been However, assemblyby
material displaced oriented
the tool.product families
For tool with are
wear hardly
land,toWu’s
find.
demand
carried ofoutcustomization, being atand
for identification the modeling
same time of in aprocess
global On the product
indentation model family level, products
was simplified by Chiou differ
and mainly
Liang [7] in to
twoa
competition
damping in with the competitors
literature. Usingall over the world. approaches,
experimental This trend, main characteristics:
piecewise (i) thedamper
linear viscous numberbyofthe components
assumption andof(ii)
smallthe
which
Altintasis etinducing the development
al. [1] developed a dynamicfrom force macro to micro
model where the type of components
amplitude vibrations. (e.g. mechanical,
Chiou’s model electrical,
was further electronical).
extended by
markets,
dynamic results
cutting in diminished
force coefficients lotwere
sizesidentified
due to augmenting
by dynamic Classical
Ahmadi andmethodologies considering
Ismail [8] to develop mainlyviscous
equivalent single model
products of
product
cutting varieties
tests using (high-volume to low-volume
a fast tool servo. Later, Budak production)
and Tunc[1]. [2] or solitary,
process alreadywhich
damping existing wasproduct families
integrated into analyze
the Semi- the
To cope with
identified the this augmenting
process dampingvariety as well
coefficients by as to be ablethe
determining to product structure
Discretization on a physical
Method level (components
to establish the stability level)
lobes. which
Since
identify possible optimization potentials in the existing causes difficulties regarding an efficient definition and
production
2212-8271 ©system,
2018 The it is important
Authors. Publishedtobyhave a precise
Elsevier Ltd. Thisknowledge
is an open access comparison
article under theofCC different
BY-NC-ND product
license families. Addressing this
2212-8271 © 2018 The Authors. Published by Elsevier Ltd.
(http://creativecommons.org/licenses/by-nc-nd/3.0/)
This is an open
Peer-review underaccess article under
responsibility the CC BY-NC-ND
of the International Scientificlicense (https://creativecommons.org/licenses/by-nc-nd/4.0/)
Committee of the 8th CIRP Conference on High Performance Cutting (HPC 2018)..
Selection ©
2212-8271 and peer-review
2017 under
The Authors. responsibility
Published of the
by Elsevier International Scientific Committee of the 8th CIRP Conference on High Performance Cutting
B.V.
(HPC 2018).
Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018.
10.1016/j.procir.2018.08.232
 Chang Cao et al. / Procedia CIRP 77 (2018) 106–109 107
2 Author name / Procedia CIRP 00 (2018) 000–000

the cutting edge of honed tools are not perfectly sharp, but regenerative component as follows:
have a small radius actually, the cutting material is easier to h(t ) st sin  j  [u(t  T )  u(t )] (3)
be extruded under the tool, which leads to more significant
process damping effect. Existing analytical methods where st is the feed rate per tooth and u(t  T ) , u (t ) are the
developed for tools with wear land, as far as we know, can not dynamic displacements of the j th tooth at the previous and
be directly extended to honed tools. present tooth periods, respectively.  T 2 / N  is the tooth
In this paper, an analytical method for modeling of process passing period. N is the number of teeth.  (rad/s) is the
damping in milling operation with the honed tools is spindle rotational angular speed.
developed. First, the ploughing force is calculated by the As illustrated in Fig. 1b, a sinusoidal surface left behind in
specific indentation coefficient which is calibrated by negative direction of u is generated when the rotating and
experiments, and the extruded volume to account for the vibrating milling cutter is fed into the workpiece. The
effect of process damping. The extruded volume can be indentation arises the ploughing forces Frp , j , Ftp , j in normal
calculated analytically with the assumption of small amplitude r and tangential t directions on the tool flank face as shown
vibrations. Then, the equivalent process damping coefficient in Fig. 1a. In evaluation of ploughing force, Wu [6] assumed
is derived analytically based on energy dissipation principle that Frp , j , F tp , j are formulated according to:
which is used to establish the relationship between the  Frp , j K spV j ; V j bS j
ploughing force and equivalent process damping coefficient. (4)
Ftp , j   Frp , j
Consequently, the equivalent process damping coefficient is
integrated into the Full-Discretization Method to plot stability where K sp is the specific indentation coefficient which
lobes diagrams. The predicted stability is verified by depends on the mechanical properties of the material,  is
comparing with the stability predicted by the existing process the mean friction coefficient, V j is the volume of the extruded
damping model [5] and the experimental results in Ref [4]. material under the j th tooth, S j is the indentation area.
This indentation model was shown to be the main source of
2. Analytical modeling of process damping process damping generated between the tool and workpiece.
The ploughing forces Frp , j , Ftp , j are determined by Eq. (4) for
The 2 DOF end milling dynamic system is illustrated in modeling of process damping, where the extruded volume V j
Fig. 1a. The modal stiffness, mass and damping in the normal needs to be developed in an explicit form. Our work focuses
y and feed x directions are denoted as K y , M y , C y and on calculating the extruded volume in the following.
K x , M x , C x respectively.
2.1. Calculation of the extruded volume
Ky Cy
y
u The Schematic of the indentation area is illustrated in Fig.
 st Ftp , j v
 v 1b. A is the separation point which partitions the work
Cx j u L C
F d ( )
Frp , j x
O
D r material into two parts. The material above the boundary L ,
G

Kx ex
E

 A  i.e. the trajectory of the point A , forming the work surface
c B
after machining, flows up to be the chip over the rake face of
the cutting edge and leads to the occurrence of shearing
(a) (b)
cutting forces. While the material below the boundary L is
Fig. 1. (a) 2DOF end milling geometry (b) flank-workpiece interaction displaced downward and extruded beneath the tool nose
region and departs from the rake face causing the generation
The cutting force components exerting on the j th tooth in
of ploughing forces eventually. B is the lowest point on the
the radial and tangential directions are Fu , j and Fv , j ,
tool surface contour. C is the intersection of the tool flank
respectively. Due to the shearing and ploughing mechanisms,
face with the boundary L . The length of the segment OA is
the radial and tangential cutting forces Fu , j , Fv , j are
the honed radius r . The clearance angle of tool is  . The
composed of shearing and ploughing components as follows:
angle between segments OB and OA is regarded as the
F
u, j Fus , j  Fup , j separation angle  . The length of the segment BD is the
(1)
F
v, j Fvs , j  Fvp , j penetration depth  . As known, the area surrounded by the
boundary L and the surface ABC represents the indentation
where s denotes shearing and p denotes ploughing. The area S j . During the dynamic cutting, subarea BCD varies
shear forces can be obtained as: dramatically due to the tool vibration while the area ABD
Fus , j ( j ) Ku bh, Fvs , j g ( j ) K v bh;
g remains relatively constant when a small tool vibration takes
(2) place. This constant area of the extruded material would
1 st  mod( j ,2 )  ex
g ( j )   produce a constant force exerted on the tool which has litter
0 otherwise influence on the dynamics of the cutting process. Thus, based
where K u and K v are the radial and tangential cutting force on the assumption of small amplitude vibrations, the extruded
coefficients, respectively, b is the axial depth of cut,  j is volume V j can be reduced effectively as:
the immersion angle, g ( j ) is a unit step function between V j  b  S ( BCD) (5)
tool engagement start and exit angles  st , ex to determine
For convenience, the toolpath is assumed to be a sinusoidal
whether the tooth is in or out of cut. h is the dynamic chip
wave of amplitude U and length L1 , thus the displacement
thickness which consists of the static component and the
108 Chang Cao et al. / Procedia CIRP 77 (2018) 106–109
Author name / Procedia CIRP 00 (2018) 000–000 3

u and the oscillating velocity u of the separation point Fup , j  Cep u

A(v, u ) can be described as: (12)
Fvp , j = Fup , j
du du dv
uU sin( v); u   U  cos(v)  vc ;  2 / L1 The energy balance relation is established [2] to calculate
dt dv dt equivalent process damping coefficient Cep .
F is assumed to be an arbitrary point on the curve L The energy dissipated by the ploughing force Frp , j and
which has a horizontal distance  from the vertical line BD . Ftp , j in radial direction u for one cycle is
From the given geometry in Fig. 2, the displacement of point Tsp N
F can be presented as:  Ei  F
0
j 1
rp , j (cos    sin  )udt (13)
uF (v, 
) U sin[ (v  r sin    )]
Likewise, the energy dissipated by the equivalent viscous
Thus, the length of segment FG , i.e. d ( ) in Fig. 1b, can be damper with coefficient Ceq lumped to the radial direction
defined as : during the period Tsp would be:
( ) uF (v,  )  uD     tan 
d 0    c Tsp N

=U sin[ (v  r sin    )]  U sin[ (v  r sin  )] (6) Ed

   C
0
j 1
eq uudt (14)
    tan 
By equating Ei and Ed , the coefficient of equivalent
where  c defines the location of point C . viscous damping Ceq is obtained as:
 c can be obtained under the boundary condition of bKsp r 2 (1  cos  )sin  (cos    sin  ) / (v tan  )
Ceq  (15)
d (c )  0 at point C . Once  c is determined, the indentation
area S ( BCD) can be calculated by integrating d ( ) from 0
to  c . Based on Eq. (6), S ( BCD) can be obtained as: 3 Stability Prediction
sin(c ) Based on Eqs. (1), (2) and (12), the tangential and radial
S(BCD)  U sin[ (v  r sin  )]  (  c )
 (7) cutting forces can be expressed in terms of tool deflections in
U cos[ (v  r sin  )] the x and y directions. The total cutting forces in the x and
  [1  cos( c )]   c  ( tan  ) / 2
2


c
y directions are obtained by the summation of tangential and
With the assumption of small amplitude vibrations, U  0 , radial cutting forces exerting on all teeth engaged in the cut:
cos(c )  1 , sin(c )  c , c   / tan r can be obtained.  Fx  N  Fv , j   s  
Therefore, S ( BCD) in Eq. (7) can be simplified as: F      Tj    bA   t   Δp   Bp
 Fy  j 1  Fu , j  0 
S ( BCD)   2 / (2 tan  ) (8) Δp  p(t )  p(t  T )；
Since points A and D are very close, the segment of the N N   cos  j  sin  j  (16)
wave AD can be assumed to be linear. Consequently, the A   Aj;B   B j ; Tj  sin 
j 1 j 1  j  cos  j 
penetration depth  can be obtained as function of the
instantaneous slope  , separation angle  and hone radius K   
 A j g( j )Tj  v  rj ; B j g ( j )Ceq Tj   rj
r as follows:  Ku  1
  r[1  cos(   ) / cos  ]  r (1  cos   sin  tan  ) (9) As a result, the governing dynamic equation of the
where  can be obtained as: vibration system is expressed eventually as:
du  s  
tan =  (u ) / vc ; vc 
 Dt / 2 Mp  Cp   Kp bA   t   Δp   Bp
dv
(10) 0 
 x(t )  (17)
sin  j
rjp; rj 
u cos  j  , p 
 y (t )  M x 0  C x 0  Kx 0 
   M   ; C  ;K  0 K 
 0 My  0 Cy   y
u is the radial velocity, vc is the cutting speed, Dt is the
diameter of the cutter. The equivalent process damping coefficient in Eq. (15) is
Substitute Eqs. (8), (9) and (10) into Eq. (5), the extruded integrated into the Full-Discretization Method (FDM) [9] for
volume V j are obtained as: stability prediction. Let q (t ) Mp  Cp / 2 and x(t ) denotes
p(t ) q(t ) . Accordingly, Eq. (17) can be transformed in the
T

V j  br 2 [1  cos   u(sin  ) / vc ]2 / (2 tan  ) (11) state space form as:

Based on Eqs. (4) and (11), the ploughing forces on the x(t ) L0 x(t )  L(t )x(t )  R(t )x(t  T ) (18)
tool flank face can be formulated eventually.
where
2.2. Equivalent process damping coefficient  M -1C / 2 M 1 
L0   ;
The idea to replace the nonlinear damper by an equivalent 1 1
CM C / 4  K CM / 2 
linear viscous damper, Ceq , is utilized for modeling of
 0 0   0 0
process damping. Therefore the radial and
 tangential process L(t )  ; R (t ) 
1 1  
damping force can also be expressed as: bA  BM C / 2 BM   bA 0 

4 Author name / Procedia CIRP 00 (2018) 000–000
The details of FDM refer to Ref. [9]. An example is
presented next to visualize the stability predicted by FDM
based on the analytical process damping model.
4 Simulation and Discussion
Ahmadi’s [4] experiments are adopted to verify the
analytical model. Full immersion cuts were performed at
constant feedrate of 0.12 mm/tooth. The milling tool was a 19
mm diameter endmill with three teeth. The hone radius and
clearance angle were measured as 15 μm and 8 deg. The
radial and tangential cutting force coefficients were identified
as K u =480 MPa, and K v =1550 MPa. The separation angle is
assumed to be constant at 50 deg [4]. The indentation
coefficient K sp and the friction coefficient  for AISI 1018
workpiece were used as 14130 N/mm3 and 0.72, respectively.
The modal parameters are applied as Table 2 in Ref. [4].
The stability lobes computed by FDM based on the
proposed analytical model are plotted in Fig. 2. The process
damping model in Ref. [5] with different calculation of the
extruded volume is also based on the assumption of small
amplitude vibrations. For comparison, the experimental
results in Ref. [4] and the stability lobes predicted by the
process damping model in Ref. [5] are also given. It shows the
stability lobes computed by the analytical model are almost
consistent with the stability lobes computed by the process
damping model in Ref. [5], which demonstrates the validity of
the proposed process damping model. However, the stability
limits in low speed region predicted by both models are
conservative comparing with the experimental results in Ref.
[4]. It is due to the reason that both the models are based on
the assumption of small amplitude vibrations. The calculation
of indentation area with the assumption of small amplitude
vibrations in the analytical model is simplified as the area of
S ( BDE ) as shown in Fig. 1b where the tool moves down a
convex surface, which underestimates the energy dissipated
by ploughing forces. Thus, the calculation of equivalent
process damping coefficient Ceq is underestimated and the
predicted stability is conservative.
4.5
axial depth of cut (mm)
4 Stable
3.5
3
2.5
3.5
2 3
2.5
1.5 700 800 900 1000
500 1000 1500 2000
Spindle speed (rev/min)
Fig. 2 Stability lobes computed using the analytical model and model in Ref.
[5]. Experimental results reproduced from Ref. [4].
Due to the nonlinear nature of process damping, the cutting
process can be in three states [10]: fully stable state, finite
amplitude state and fully unstable state. The lower bound of
the stability lobes are developed by Ahmadi and Ismail [10]
for fully stable state based on the assumption of small
amplitude vibrations, which are also conservative greatly
compared with the stability lobes computed using empirical
damping model and the experimental results in Ref. [1]. The
Chang Cao et al. / Procedia CIRP 77 (2018) 106–109 109
stability lobes computed by the proposed analytical model can
also be regarded as the lower bound of the stability lobes. It is
appropriate to have an assumption of small amplitude
vibrations deriving the mathematical equations considering
that the primary reason for studying chatter is to eliminate it at
an early stage when the amplitude of vibration is still small. In
fact, the boundaries computed under the assumption of small
amplitude vibrations are commonly applied in the literature to
define stability limits.
5 Conclusion
This paper develops an analytical method to deal with the
problem of process damping for honed tool with cutting edge
radius. The extruded volume can be calculated analytically in
analytical model based on the assumption of small amplitude
vibrations. Consequently, the equivalent process damping
coefficient can be calculated analytically, which can be
included in the Full-Discretization Method to establish the
stability lobes. The proposed analytical model is verified by
the process damping model in Ref. [5] and the predicted
stability is meaningful for practical machine although
conservative. In general, the analytical method is applicable
and meaningful for stability prediction considering the effect
of process damping in milling operation with the honed tool.
Acknowledgments
This work was partially supported by the National Natural
Science Foundation of China (91648113, 51705176) and the
National Basic Research Program of China (2013CB035800).
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