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Dynamics and Machining Stability for Flexible Systems
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Dynamics and Machining Stability for Flexible Systems

A special issue of Journal of Manufacturing and Materials Processing (ISSN 2504-4494).

Deadline for manuscript submissions: 30 June 2025 | Viewed by 7726

Special Issue Editors

Dr. Zekai Murat Kilic

E-Mail Website
Guest Editor
Department of Mechanical, Aerospace and Civil Engineering, School of Engineering, Faculty of Science and Engineering, The University of Manchester, Manchester M13 9PL, UK
Interests: machining dynamics; chatter stability; mechanical vibrations; process control; intelligent tooling; metal cutting
Prof. Dr. Jixiang Yang

E-Mail Website
Guest Editor
School of Mechanical Science & Engineering, Huazhong University of Science and Technology, Wuhan 430074, China
Interests: multi-axis intelligent CNC machining; robot precision measurement; surface quality control
Special Issues, Collections and Topics in MDPI journals
Dr. Mohit Law

E-Mail Website
Guest Editor
Machine Tool Dynamics Laboratory, Department of Mechanical Engineering, Indian Institute of Technology Kanpur, Kanpur 208016, India
Interests: modal analysis; machining; vibration control; machining stability

Special Issue Information

Dear Colleagues,

Multi-axis milling, turning, and grinding of thin-walled structures using flexible machining systems such as slender tools and flexible robotic arms integrated with spindles have many inherent challenges due to vibrations and chatter as well as dimensional errors. Recent innovations in tooling, AI-assisted approaches, and process modelling promise near optimal cutting performance by minimizing vibrations and compensating for errors.

In this JMMP Special Issue, we invite submissions related but not limited to the following topics:

-  Modelling, simulation, or digital twinning solutions of machine tool vibrations and chatter stability with flexible machining systems such as thin-walled milling, shell turning, and robotic machining;

- System identification, modal analysis, or process monitoring of flexible systems;

-  Chatter avoidance in flexible machining systems through active and passive damping solutions, tool geometry design, or path planning strategies;

- Active control in compliant grinding such as robotic polishing;

- Use of Artificial Intelligence and Machine Learning in vibration prediction and control;

- Nonlinearities in flexible machining systems;

- Special challenging processes such as turn-milling, vibration-assisted machining, or micro-machining;

- Challenges associated with the machining of additively manufactured components.

Dr. Zekai Murat Kilic
Prof. Dr. Jixiang Yang
Dr. Mohit Law
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Journal of Manufacturing and Materials Processing is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 1800 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • digital twin
  • chatter stability
  • thin-walled machining
  • flexible machining systems
  • robotic machining
  • chatter avoidance
  • artificial intelligence
  • machine learning
  • compliant grinding
  • polishing
  • system identification
  • process monitoring

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Published Papers (6 papers)

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Research

27 pages, 14826 KiB  
Article
Feed Drive Control and Non-Linear Friction Interaction Effect on Machining Chatter Stability Prediction
by Oier Franco, Xavier Beudaert, Kaan Erkorkmaz and Jokin Munoa
J. Manuf. Mater. Process. 2024, 8(5), 207; https://doi.org/10.3390/jmmp8050207 - 24 Sep 2024
Viewed by 899
Abstract
In large-scale machine tool applications, the presence of low structural natural frequencies limits the cutting capabilities of the machine. The machine tool joints interact with the structural mode shapes, hence, the feed drive system characteristics can significantly influence the resultant dynamics at the [...] Read more.
In large-scale machine tool applications, the presence of low structural natural frequencies limits the cutting capabilities of the machine. The machine tool joints interact with the structural mode shapes, hence, the feed drive system characteristics can significantly influence the resultant dynamics at the cutting point. This paper investigates the effect of guideway non-linear friction and feed drive motion control parameters on chatter stability predictions. Field experimentation on seven machines reveals substantial differences between in-motion and idle dynamics, leading to errors in traditional process stability predictions. By using a one-degree-of-freedom model that incorporates non-linear friction and controller forces together with motion commands, the effect of axis motion on machine tool dynamics is analyzed. Later, the feed and force non-linearities are studied in a large-scale machine tool using traditional and alternative dynamic characterization techniques. The findings demonstrate that both feed and force non-linearities influence the frequency response functions at the cutting points, ultimately affecting the accuracy of process stability predictions. Proper selection of feed drive control parameters reduces the cutting point compliance, improving machine tool productivity by up to 50%. Full article
(This article belongs to the Special Issue Dynamics and Machining Stability for Flexible Systems)
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26 pages, 8585 KiB  
Article
Fundamental Investigation of the Application Behavior and Stabilization Potential of Milling Tools with Structured Flank Faces on the Minor Cutting Edges
by Raphael Isaak Elias Schönecker, Jonas Baumann, Rafael Garcia Carballo and Dirk Biermann
J. Manuf. Mater. Process. 2024, 8(4), 174; https://doi.org/10.3390/jmmp8040174 - 10 Aug 2024
Cited by 1 | Viewed by 1021
Abstract
In milling processes in which material removal is performed periodically from solid material, dynamic effects are generally considered to be responsible for instabilities and subsequent productivity limits. Usually, in such applications, the process-inherent complex dynamic load spectrum on machines, tools and workpieces is [...] Read more.
In milling processes in which material removal is performed periodically from solid material, dynamic effects are generally considered to be responsible for instabilities and subsequent productivity limits. Usually, in such applications, the process-inherent complex dynamic load spectrum on machines, tools and workpieces is considered together with vibration-based relative displacements that can be attributed to the regenerative effect. There are numerous techniques in the literature addressing the suppression of these dynamic effects, but they require a large amount of analysis and implementation effort as well as specific expert knowledge. The approach presented here, however, provides a universally applicable method for suppressing chatter vibrations and deflections. By applying structure elements to the flanks of the minor cutting edges of HSS end mills, it was possible to increase the chatter-free limiting depth of cut ap,crit in the milling processes of the aluminum alloy EN AW-7075. Structured tools were used in ramp milling tests to investigate various effects, such as the influence of certain geometric design features on the stabilization potential compared to a reference tool. Furthermore, the effects of varied process parameter configurations and wear-related effects on the performance of the tool concept were focused on as well. The three key design features of the cutting edge and the structured profiles were identified from the results of the investigation, which, when combined in the most efficient design, in each case led to the development of an optimized structure and process configuration with cumulative potential for increasing the stability limit up to 200%. Full article
(This article belongs to the Special Issue Dynamics and Machining Stability for Flexible Systems)
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21 pages, 21234 KiB  
Article
Real-Time Milling Chatter Detection and Control with Axis Encoder Feedback and Spindle Speed Manipulation
by Hakan Çalışkan
J. Manuf. Mater. Process. 2024, 8(4), 173; https://doi.org/10.3390/jmmp8040173 - 10 Aug 2024
Viewed by 1193
Abstract
This paper introduces a complete real-time algorithm, where the chatter is detected and eliminated by spindle speed manipulation via the chatter energy feedback calculated from the axis encoder measurement. The proposed method does not require profound knowledge of the machining dynamics; instead, the [...] Read more.
This paper introduces a complete real-time algorithm, where the chatter is detected and eliminated by spindle speed manipulation via the chatter energy feedback calculated from the axis encoder measurement. The proposed method does not require profound knowledge of the machining dynamics; instead, the entire algorithm exploits the fact that milling vibrations consist of forced vibrations at spindle speed harmonics and chatter vibrations that are close to one of the natural modes, with sidebands which are spread at the multiples of spindle speed frequency above and below the chatter frequency. The developed algorithm is able to identify the amplitude, phase and frequency of all the harmonics constituting the periodic forced and chatter vibrations. The key challenge is to select dominant chatter frequencies for the calculation of a robust and accurate chatter energy ratio feedback; this is achieved by utilizing the frequency estimation variance of EKF as a novel chatter indicator. Based on the chatter energy ratio feedback, the controller overrides the spindle speed in order to suppress the chatter energy below a particular threshold value. The varying spindle speed challenge is handled by updating the state transition matrices of the Kalman filters and real-time calculation of the band-pass filter coefficients, based on the derived discrete time transfer functions. The developed algorithm is tested on a Deckel FP5cc CNC which is in-house retrofitted and has a PC-based controller for the real-time application of the proposed algorithm. It is shown that the real-time chatter frequency and amplitude estimates are compatible with off-line FFT analysis, and chatter can be successfully eliminated by energy feedback. Full article
(This article belongs to the Special Issue Dynamics and Machining Stability for Flexible Systems)
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11 pages, 4766 KiB  
Article
Tool Path Strategies for Efficient Milling of Thin-Wall Features
by Lutfi Taner Tunc and Deniz Arda Gulmez
J. Manuf. Mater. Process. 2024, 8(4), 169; https://doi.org/10.3390/jmmp8040169 - 5 Aug 2024
Cited by 1 | Viewed by 1168
Abstract
The milling of thin-wall geometries has been a challenge due to inherent chatter vibrations and workpiece deflections. Moreover, tool path generation strategies in CAD-CAM systems are not able to fully address all such concerns. The objective of this study is to demonstrate potential [...] Read more.
The milling of thin-wall geometries has been a challenge due to inherent chatter vibrations and workpiece deflections. Moreover, tool path generation strategies in CAD-CAM systems are not able to fully address all such concerns. The objective of this study is to demonstrate potential 5-axis milling tool path strategies, which do not exist in the conventional tool path generation. The demonstration is performed for increased efficiency in milling of thin-wall features considering the main limitation of chatter. The effects of varying workpiece dynamics on milling stability are shown in case studies through simulations and cutting experiments. Based on the simulation results, tool path strategies are developed. The effect of tool path generation and the relation to parameter selection are highlighted. Most of the discussion relies on previously reported experimental results. The results showed that by tailoring the tool path considering the concerns and limitations associated with thin-wall part structure and geometry, it is possible to increase productivity by at least two folds. Full article
(This article belongs to the Special Issue Dynamics and Machining Stability for Flexible Systems)
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22 pages, 10471 KiB  
Article
Improving Robotic Milling Performance through Active Damping of Low-Frequency Structural Modes
by Govind Narayan Sahu, Andreas Otto and Steffen Ihlenfeldt
J. Manuf. Mater. Process. 2024, 8(4), 160; https://doi.org/10.3390/jmmp8040160 - 27 Jul 2024
Viewed by 837
Abstract
Industrial robots are increasingly prevalent due to their large workspace and cost-effectiveness. However, their limited static and dynamic stiffness can lead to issues like mode coupling chatter and regenerative chatter in robotic milling processes, even at shallow cutting depths. These problems significantly impact [...] Read more.
Industrial robots are increasingly prevalent due to their large workspace and cost-effectiveness. However, their limited static and dynamic stiffness can lead to issues like mode coupling chatter and regenerative chatter in robotic milling processes, even at shallow cutting depths. These problems significantly impact performance, product quality, tool longevity, and can damage robot components. An active inertial actuator was deployed at the milling spindle to enhance dynamic stiffness and suppress low-frequency vibrations effectively. It was identified that the characteristics of the actuator change with its mounting orientation, a common scenario in robotic machining processes. This variation has not been reported in the literature. Our study includes the identification of model parameters for the actuator in both horizontal and vertical mountings. Additionally, the novelty of the present work lies in the specific design and implementation of compensation filters tailored for the active inertial actuator in both horizontal and vertical configurations. These filters address the unique challenges posed by low-frequency vibrations in robotic milling, offering significant improvements in dynamic stiffness and vibration suppression. Traditional model-based compensators were effective for vertical mounting, while pole-zero placement techniques with minimum phase systems were optimal for horizontal mounting. These compensators significantly enhanced dynamic stiffness, reducing maximum low-frequency robot structural modes by approximately 100% in horizontal mounting and approximately 214% in the vertical configuration of the actuator. This advancement promises to enhance industrial robot capabilities across diverse machining applications. Full article
(This article belongs to the Special Issue Dynamics and Machining Stability for Flexible Systems)
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16 pages, 1316 KiB  
Article
Stability of Micro-Milling Tool Considering Tool Breakage
by Yuan-Yuan Ren, Bao-Guo Jia, Min Wan and Hui Tian
J. Manuf. Mater. Process. 2024, 8(3), 122; https://doi.org/10.3390/jmmp8030122 - 11 Jun 2024
Viewed by 1335
Abstract
Micro-milling, widely employed across various fields, faces significant challenges due to the small diameter and limited stiffness of its tools, making the process highly susceptible to cutting chatter and premature tool breakage. Ensuring stable and safe cutting processes necessitates the prediction of chatter [...] Read more.
Micro-milling, widely employed across various fields, faces significant challenges due to the small diameter and limited stiffness of its tools, making the process highly susceptible to cutting chatter and premature tool breakage. Ensuring stable and safe cutting processes necessitates the prediction of chatter by considering the tool breakage. Crucially, the modal parameters of the spindle–holder–tool system are important prerequisites for such stability prediction. In this paper, the frequency response functions (FRFs) of the micro-milling tool are calculated by direct FRFs of the micro-milling cutter and cross FRFs between a point on the shank and one on the tool tip. Additionally, by utilizing a cutting force model specific to micro-milling, the bending stress experienced by the tool is computed, and the tool breakage curve is subsequently determined based on the material’s permissible maximum allowable stress. The FRFs of the micro-milling tool, alongside the tool breakage curve, are then integrated to generate the final stability lobe diagrams (SLDs). The effectiveness and reliability of the proposed methodology are confirmed through a comprehensive series of numerical and experimental validations. Full article
(This article belongs to the Special Issue Dynamics and Machining Stability for Flexible Systems)
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