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Journal of Vibration Testing and System Dynamics 1(1) (2017) 35--52 | DOI:10.5890/JVTSD.2017.03.003

Eric B. Halfmann$^{1}$, C. Steve Suh$^{1}$, Wayne N.P. Hung$^{2}$

$^{1}$ Nonlinear Engineering and Control Lab, Department of Mechanical Engineering, Texas A&M University, College Station, TX 77843-3123, USA

$^{2}$ Engineering Technology and Industrial Distribution Department, Texas A&M University, College Station, TX 77843-3367, USA

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Abstract

A comprehensive three-dimensional turning model is validated by comparing numerical simulations to the experimental data obtained in Part 1 using instantaneous frequency. Comparison of chatter-free cutting demonstrates that the model effectively captures the work- piece natural frequency, tool natural frequency, a nonlinear mode, and the spindle speed, which are main components of the underlying dynamics observed experimentally. The model accurately simulates chatter vibrations characterized as increased vibration amplitude and the appearance of coupled tool õworkpiece vibrations at a chatter frequency. The stability diagram constructed by running the model at various spindle speeds and depth-of-cuts demonstrates a general increase in the chatter-free critical depth-of-cut as the spindle speed increased. This chatter-free limit levels out as the spindle speeds exceeded 1500 rpm. At high spindle speeds the workpiece motions dominate the cutting dynamics, resulting in cases of excessive work- piece vibration amplitude and highly nonlinear frequencies which af- fect the efficiency of the process. The excessive workpiece amplitude cases create a second stability limit to be considered as a result of imbalance and configuration of the workpiece. Thus, workpiece dy- namics should not be neglected in mathematical and experimental analyses for the design of machine tools and robust cutting control law.

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