Increased stability of low-speed turning through a distributed force and continuous delay model

machining. In the past, this improved stability has been attributed to the energy dissipated by the interference between the workpiece and the tool relief face. In this study, an alternative physical explanation is described. In contrast to the conventional approach, which uses a point force acting at the tool tip, the cutting forces are distributed over the tool-chip interface. This approximation results in a second-order delayed integrodifferential equation for the system that involves a short and a discrete delay. A method for determining the stability of the system for an exponential shape function is described, and temporal finite element analysis is used to chart the stability regions. Comparisons are then made between the stability charts of the point force and the distributed force models for continuous and interrupted turning. DOI: 10.1115/1.3187153

[1]  Y. S. Tarng,et al.  Modeling of the process damping force in chatter vibration , 1995 .

[2]  Yung C. Shin,et al.  A comprehensive chatter prediction model for face turning operation including tool wear effect , 2002 .

[3]  Nathan H. Cook,et al.  Self-Excited Vibrations in Metal Cutting , 1959 .

[4]  Gábor Stépán,et al.  Lobes and Lenses in the Stability Chart of Interrupted Turning , 2006 .

[5]  H. E. Merritt Theory of Self-Excited Machine-Tool Chatter: Contribution to Machine-Tool Chatter Research—1 , 1965 .

[6]  Brian P Mann,et al.  An empirical approach for delayed oscillator stability and parametric identification , 2006, Proceedings of the Royal Society A: Mathematical, Physical and Engineering Sciences.

[7]  Joseph A. Arsecularatne On tool-chip interface stress distributions, ploughing force and size effect in machining , 1997 .

[8]  C. Leyens,et al.  Titanium and titanium alloys : fundamentals and applications , 2005 .

[9]  R. Boyer An overview on the use of titanium in the aerospace industry , 1996 .

[10]  Krzysztof Jemielniak,et al.  Numerical simulation of non-linear chatter vibration in turning , 1989 .

[11]  B. Mann,et al.  Stability of Interrupted Cutting by Temporal Finite Element Analysis , 2003 .

[12]  D. William Wu,et al.  Application of a comprehensive dynamic cutting force model to orthogonal wave-generating processes , 1988 .

[13]  Francis C. Moon,et al.  Dynamics and chaos in manufacturing processes , 1998 .

[14]  Brian P. Mann,et al.  Stability of Delay Equations Written as State Space Models , 2010 .

[15]  J. A. Bailey,et al.  Friction in metal machining—Mechanical aspects , 1975 .

[16]  N. K. Chandiramani,et al.  Dynamics of 2-dof regenerative chatter during turning , 2006 .

[17]  Steven Y. Liang,et al.  Chatter stability of a slender cutting tool in turning with tool wear effect , 1998 .

[18]  E. B. Magrab,et al.  Improved Methods for the Prediction of Chatter in Turning, Part 2: Determination of Cutting Process Parameters , 1990 .

[19]  R. L. Kegg,et al.  An Explanation of Low-Speed Chatter Effects , 1969 .

[20]  Y. S. Tarng,et al.  An analytical model of chatter vibration in metal cutting , 1994 .

[21]  Viswanathan Madhavan,et al.  Direct Observations of the Chip-Tool Interface in the Low Speed Cutting of Pure Metals , 2002 .

[22]  G. J. DeSalvo,et al.  On the Plastic Flow Beneath a Blunt Axisymmetric Indenter , 1970 .

[23]  D. W. Jordan,et al.  Nonlinear ordinary differential equations : an introduction to dynamical systems , 1999 .

[24]  G. Stépán Retarded dynamical systems : stability and characteristic functions , 1989 .