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Application of mechanical micromachining for fabricating complex three-dimensional (3D) micro-scale features and small parts on a broad range of materials has increased significantly in the recent years. In particular, mechanical micromachining finds applications in manufacturing of biomedical devices, tribological surfaces, energy storage/conversion systems, and aerospace components. Effectively addressing the dual requirements for high accuracy and high throughput for micromachining applications necessitates understanding and controlling of dynamic behavior of micromachining system, including positioning stage, spindle, and the (micro-) tool, as well as their coupling with the mechanics of the material removal process. The dynamic behavior of the tool-collet-spindle-machine assembly, as reflected at the cutting edges of a micro-tool, often determines the achievable process productivity and quality. However, the common modeling techniques (such as beam based approaches) used in macro-scale to model the dynamics of cutting tools, cannot be used to accurately and efficiently in micro-scale case. Furthermore, classical modal testing techniques poses significant challenges in terms of excitation and measurement requirements, and thus, new experimental techniques are needed to determine the speed-dependent modal characteristics of miniature ultra-high-speed (UHS) spindles that are used during micromachining. The overarching objective of this thesis is to address the aforementioned issues by developing new modeling and experimental techniques to accurately predict and analyze the dynamics of micro-scale cutting tools and miniature ultra-high-speed spindles, including rotational effects arising from the ultra high rotational speeds utilized during micromachining, which are central to understanding the process stability. Accurate prediction of the dynamics of micromachining requires (1) accurate and numerically-efficient analytical approach to model the rotational dynamics of realistic micro-tool geometries that will capture non-symmetric bending and coupled torsional/axial dynamics including the rotational/ gyroscopic effects; and (2) new experimental approaches to accurately determine the speed-dependent dynamics of ultra-high-speed spindles. The dynamic models of cutting tools and ultra-high-speed spindles developed in this work can be coupled together with a mechanistic micromachining model to investigate the process stability of mechanical micromachining. To achieve the overarching research objective,first, a new three-dimensional spectral- Tchebychev approach is developed to accurately and efficiently predict the dynamics of (micro) cutting tools. In modeling the cutting tools, considering the efficiently and accuracy of the solution, a unified modeling approach is used. In this approach, the shank/taper/extension sections, vibrational behavior of which exhibit no coupling between different textural motion, of the cutting tools are modeled using one-dimensional (1D) spectral-Tchebychev (ST) approach; whereas the fluted section (that exhibits coupled vibrational behavior) is modeled using the developed 3D-ST approach. To obtain the dynamic model for the entire cutting tool, a component mode synthesis approach is used to `assemble' the dynamic models. Due to the high rotational speeds needed to attain high material removal rate while using micro tools, the gyroscopic/rotational effects should be included in predicting the dynamic response at any position along the cutting edges of a micro-tool during its operation. Thus, as a second step, the developed solution approach is improved to include the effects arising from the high rotational speeds. The convergence, accuracy, and efficiency of the presented solution technique is investigated through several case studies. It is shown that the presented modeling approach enables high-fidelity dynamic models for (micro-scale) cutting-tools. Third, to accurately model the dynamics of miniature UHS spindles, that critically affect the tool-tip motions, a new experimental (modal testing) methodology is developed. To address the deficiency of traditional dynamic excitation techniques in providing the required bandwidth, repeatability, and impact force magnitudes for accurately capturing the dynamics of rotating UHS spindles, a new impact excitation system (IES) is designed and constructed. The developed system enables repeatable and high-bandwidth modal testing of (miniature and compliant) structures, while controlling the applied impact forces on the structure. Having developed the IES, and established the experimental methodology, the speed-dependent dynamics of an air bearing miniature spindle is characterized. Finally, to show the broad impact of the develop modeling approach, a macro-scale endmill is modeled using the presented modeling technique and coupled to the dynamics of a (macro-scale) spindle, that is obtained experimentally, to predict the tool-point dynamics. Specific contributions of this thesis research include: (1) a new 3D modeling approach that can accurately and efficiently capture the dynamics of pretwisted structures including gyroscopic effects, (2) a novel IES for repeatable, high-bandwidth modal testing of miniature and compliant structures, (3) an experimental methodology to characterize and understand the (speed-dependent) dynamics of miniature UHS spindles.

This study explores the relationship between endmill tool dynamics and cutting parameters, emphasizing the impact of these factors on machining dynamics, surface finish, and dimensional control. It introduces a novel approach to analyze and optimize the overall performance of a solid carbide endmill, with a specific focus on machining Aluminum 6066-T6. By using stability lobes diagrams (SLD), stable conditions for cutting were chosen, and then surface roughness and tool and workpiece vibration analyses were performed to assess machining performance. This work aims to understand the effects of operating below the peaks and valleys, inherent in the shape of the SLD, using different RPMs. The study's methodology involves tap tests using CutPro - Tap Test Module and milling tests on a horizontal machining center. The surface roughness measurement was performed using an Alicona Infinite Focus confocal microscope and accelerometers were positioned on the spindle bearing housing and workpiece. The findings suggest that within the stable range below the stability lobe diagram's boundary, there is a significant difference in vibration resulting in variation in surface roughness corresponding to the peaks and valleys of the SLD. The variation of acceleration, and consequently vibration, was considerably higher when operating below valleys which negatively affected the surface roughness of the workpiece. The surface roughness plays a pivotal role in tool performance and subsequently influences metal removal rate and tool and spindle life. For conditions closer to instability, this is even more important. In conclusion, this research lays the foundation for a holistic approach to solid carbide endmill design and cutting parameter selection, showing that the machining process can be optimized in terms of the SLDs, even in regions far below the stability limit / Thesis / Master of Applied Science (MASc)

The diploma thesis deals with determination of modal parameters for machine tool manage-ment. Experimental modal analysis is performed and a new method for determining the damping and stiffness of the machine tool guidance is proposed. A mathematical model for the calculation of signals using state equations was created and the damping stiffness was determined using hysteresis curves.

Regenerative chatter is a well-known machining problem that results in unstable cutting process, poor surface quality, reduced material removal rate and damage on the machine tool itself. Stability lobe diagrams supply stable depth of cut &amp / #8211 / spindle speed combinations and they can be used to avoid chatter. The main requirement for generating the stability lobe diagrams is the system dynamics information at the tool tip in the form of point frequency response function (FRF). In this work, an analytical model that uses structural coupling and modification methods for modeling the dynamics of spindle-holder-tool assemblies in order to obtain the tool point FRF is presented. The resulting FRF obtained by the model can be used in the existing analytical and numerical models for constructing the stability lobe diagrams. Timoshenko beam theory is used in the model for improved accuracy and the results are compared with those of Euler-Bernoulli beam theory. The importance of using Timoshenko beam theory in the model is pointed out, and the circumstances, under which the theory being used in the model becomes more important, are explained. The model is verified by comparing the results obtained by the model with those of a reliable finite element software for a case study. The computational superiority in using the model developed against the finite element software is also demonstrated. Then, the model is used for studying the effects of bearing and contact dynamics at the spindle-holder and holder-tool interfaces on the tool point FRF. Based on the results of the effect analysis, a new approach is suggested for the identification of bearing and interface parameters from experimental measurements, which is demonstrated on a spindle-holder-tool assembly. The model is also employed for studying the effects of design and operational parameters on the tool point FRF, from the results of which, suggestions are made regarding the design of spindles and selection of operational parameters. Finally, it is experimentally demonstrated that the stability lobe diagram of an assembly can be predicted pretty accurately by using the model proposed, and furthermore the stability lobe diagram can be modified in a predictable manner for improving chatter stability.