Machining instabilities and Preventive approaches for modern production industries

26 Sep 2022   -   30 Sep 2022
Mechanical Engineering
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Assessment of quality, cost, sustainability and productivity is made on the bases of surface integrity, tool wear, cutting power, chatter control, dimensional integrity and many other factors. At present, modeling tools are dominating in several engineering sectors. Perhaps the machine dynamics is a coupled model of tool and workpiece, which is highly nonlinear and the overall process stability depends on several operating parameters and conditions. The cutting instability sometimes called chatter is very important objective to be controlled in achieving better quality products. During the modeling process, often second-order delay differential equations in the time domain are to be solved. Time domain, frequency domain and direct simulation techniques are available for solving the infinite dimensional delay differential equations. The so-called stability diagrams are to be generated for identifying the boundaries of stability which delineate the machining parameter space into stable and unstable cutting conditions. The stable cutting conditions, which can now be chosen systematically, guarantee smooth product, ergonomic work environment and prolonged life of cutting tools and machine tools. Machining of thin-walled workpiece is of vital importance today. Especially, the design of milling process with flexible workpiece has been a topic of interest in aircraft components and other parts. With moderate depths of cut and high speeds, often the instability can be avoided. This 5-day course on instabilities and preventive approaches helps in understanding alternate methods of stability assessment in different machining techniques and different control techniques including passive, and active methods. Several case studies will be explored and participants will be given related simulation training in tutorial sessions.