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Optimisation of variable helix tool geometry for regenerative chatter mitigation

Yusoff, A.R. and Sims, N.D. (2011) Optimisation of variable helix tool geometry for regenerative chatter mitigation. International Journal of Machine Tools and Manufacture, 51 (2). pp. 133-141. ISSN 0890-6955


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It is well known that regenerative chatter can result in excessive tool wear, poor surface finish, and hence limited productivity during metal machining. Various mitigation methods can be applied to suppress chatter; however, the current paper focuses on applying optimal variable helix tool geometry. A semi discretrisation method is combined with Differential Evolution to optimise variable helix end milling tools so as to avoid chatter by modifying the variable helix and variable pitch tool geometry. The semi discretrisation method is first validated experimentally. The numerical optimisation procedure is then used to optimise tool geometry for a machining problem involving a flexible workpiece. The analysis predicted total mitigation of chatter using the optimised variable helix milling tool at a low radial immersion. However, in practice a five fold increase in chatter stability was obtained, compared to the traditional milling tool.

Item Type: Article
Copyright, Publisher and Additional Information: © 2011 Elsevier. This is an author produced version of a paper subsequently published in International Journal of Machine Tools and Manufacture. Uploaded in accordance with the publisher's self-archiving policy.
Keywords: Regenerative chatter; Variable helix; Optimisation; Milling
Institution: The University of Sheffield
Academic Units: The University of Sheffield > Faculty of Engineering (Sheffield) > Department of Mechanical Engineering (Sheffield)
Funding Information:
FunderGrant number
Depositing User: Dr Neil D Sims
Date Deposited: 05 Sep 2011 10:02
Last Modified: 08 Feb 2013 17:33
Published Version: http://dx.doi.org/10.1016/j.ijmachtools.2010.10.00...
Status: Published
Publisher: Elsevier
Refereed: Yes
Identification Number: 10.1016/j.ijmachtools.2010.10.004
URI: http://eprints.whiterose.ac.uk/id/eprint/43226

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