Abstract This paper presents a model of the dynamic cutting force process for the three-dimensional or oblique turning operation. To obtain dynamic force predictions, the mechanistic force model is linked to a tool–workpiece vibration model. Particular attention was paid to the inclusion of the cross-coupling between radial and axial vibrations in the force model. The inclusion of this cross-coupling facilitates prediction of the unstable–stable chatter phenomenon which usually occurs in certain cases of finish turning due to process non-linearity. The dynamic force model developed was incorporated into a computer program to obtain time-saving chatter predictions. Experimental tests were performed on AISI 4140 steel workpieces to justify the chatter predictions of the dynamic cutting process model in both the finishing and roughing regimes. Experimental results corroborate the unstable–stable chatter predictions of the model for different cases of finish machining. In addition, experimental results also confirmed the accuracy of chatter predictions for various cases of rough turning.
[1]
E. B. Magrab,et al.
Improved Methods for the Prediction of Chatter in Turning, Part 3: A Generalized Linear Theory
,
1990
.
[2]
I. E. Minis,et al.
Improved Methods for the Prediction of Chatter in Turning
,
1990
.
[3]
A. Galip Ulsoy,et al.
Chatter Analysis of Machining Systems with Nonlinear Force Processes
,
1996
.
[4]
Byung Ho Lee,et al.
An analytical model of dynamic cutting forces in chatter vibration
,
1991
.
[5]
Yung C. Shin,et al.
A new procedure to determine instantaneous cutting force coefficients for machining force prediction
,
1997
.
[6]
John W. Sutherland,et al.
Dynamic model of the cutting force system in the turning process
,
1990
.