Chatter avoidance in the milling of thin floors with bull-nose end mills: Model and stability diagrams

The milling of thin parts is a high added value operation where the machinist has to face the chatter problem. The study of the stability of these operations is a complex task due to the changing modal parameters as the part loses mass during the machining and the complex shape of the tools that are used. The present work proposes a methodology for chatter avoidance in the milling of flexible thin floors with a bull-nose end mill. First, a stability model for the milling of compliant systems in the tool axis direction with bull-nose end mills is presented. The contribution is the averaging method used to be able to use a linear model to predict the stability of the operation. Then, the procedure for the calculation of stability diagrams for the milling of thin floors is presented. The method is based on the estimation of the modal parameters of the part and the corresponding stability lobes during the machining. As in thin floor milling the depth of cut is already defined by the floor thickness previous to milling, the use of stability diagrams that relate the tool position along the tool-path with the spindle speed is proposed. Hence, the sequence of spindle speeds that the tool must have during the milling can be selected. Finally, this methodology has been validated by means of experimental tests.

Modelling rail corrugation with specific track parameters focusing on ballasted track and slab track

The objective of this paper is to compare 3 types of track (high performance ballasted track, STEDEF and AFTRAV) from the corrugation growth point of view. This work has considered different vehicle speeds and track radii, and the results have taken into account the four wheels of a bogie. These tracks have been studied using Finite Elements with Nastran-Patran and RACING, a tool developed in Matlab by the authors which estimates the corrugation growth tendency. The tracks are studied using the Finite Strip Method and the Periodic Structure Theory. Lateral and vertical receptances for track and vehicle have been obtained, as well as the corrugation growth functions. In the paper the tracks are ranked according to corrugation development.