Verification of pattern formation mechanism using voxel model and estimation accuracy for inverse analysis of vibration phenomenon using two-dimensional discrete Fourier transform of end mill chatter mark

Abstract

The vibration generated at the contact point between a tool blade and a machined surface during cutting significantly influences the generation mechanism of regenerated chatter vibration. However, it is difficult to measure the vibrations generated at this contact point. In our previous research, we focused on the chatter mark formed on a machined surface owing to the chatter vibration during cutting, and analyzed the periodicity of the pattern using a two-dimensional discrete Fourier transform. Furthermore, we proposed a method for inversely analyzing the chatter vibration information generated at the contact point during cutting from the periodicity of the chatter mark, and demonstrated its effectiveness. The proposed method is based on the formation mechanism of the chatter mark estimated from the geometrical relationship between the tool blade and the machined surface, and the validity of this formation mechanism has not been directly investigated. In this research, the movement of the tool blade during cutting was reproduced based on the vibration displacement of the tool shank measured in the cutting experiment. A voxel model cutting simulation was then performed using the reproduced tool blade movement, and the chatter mark was reproduced in the simulation. By comparing this reproduced pattern with the chatter mark obtained by actual processing, the validity of the inverse-analysis model proposed was verified more directly than the previous research.

Keywords

• chatter vibration
• chatter mark
• cutting
• two-dimensional fourier transform
• voxel model