The article presents results of both experimental and FEM model-based investigations on chatter phenomena that occur in the end milling process. On the basis of chatter symptoms observed during machining, the mechanism of its occurrence has been identified. Then, a FEM model has been built to indicate machine tool elements responsible for loss of stability. Afterwards, experimental modal analysis has been conducted in order to validate the FEM model. Finally, on the basis of the validated model, the structural changes have been proposed and applied in the real object resulting in increased stability.
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This article presents the methodology for modeling the stiffness of a machine tool load-bearing system using the finite element method. A new, simplified model of stiffness of the linear guide with a preload based on equivalent contact model was proposed. An equivalent contract model was developed where the ball was replaced with four rod elements of equivalent stiffness, interconnecting the opposite ends of the face of cuboidal finite ele- ments. To shorten the computation time and facilitate modeling reduction and substructur-ing methods was used. The accuracy of the proposed model was compared with experimental results. In addition, the computation times were evaluated by comparing the simplified model with the full model and other equivalent models. Then, the model was used to determine the stiffness of the machine load-bearing system on the example of a machining table using the aforementioned methods and the obtained results were com-pared in terms of accuracy (less than 1% difference in maximum displacement value) and computation time with the classic approach (up to 97% in time reduction). This paper demonstrated the validity of the proposed model, allowing accurate and fast determination of the stiffness of machine tool load-bearing system.
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