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ISSN: 2475-4811 (print)
ISSN: 2475-482X (online)
Journal of Vibration Testing and System Dynamics

C. Steve Suh (editor), Pawel Olejnik (editor),

Xianguo Tuo (editor)

Pawel Olejnik (editor)

Lodz University of Technology, Poland

Email: pawel.olejnik@p.lodz.pl

C. Steve Suh (editor)

Texas A&M University, USA

Email: ssuh@tamu.edu

Xiangguo Tuo (editor)

Sichuan University of Science and Engineering, China

Email: tuoxianguo@suse.edu.cn

Impact of Tool Geometry and Tool Feed on Machining Stability

Journal of Vibration Testing and System Dynamics 1(4) (2017) 295--317 | DOI:10.5890/JVTSD.2017.12.002

Achala V. Dassanayake; C. Steve Suh

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

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Abstract

Tool-workpiece dynamics is characterized by aperiodic responses in- cluding period-doubling bifurcation and chaos. As a state signifying the extent of machining instability, tool chatter in longitudinal turn- ing operation is a function of nonlinear regenerative cutting force, instantaneous depth-of-cut (DOC), and workpiece whirling. The ef- fects of tool geometry and feed rate per revolution on cutting stability are investigated using a comprehensive model previously reported in References [1–3]. The model configuration allows the coupled tool- workpiece motion relative to the machining surface to be studied in the Cartesian space as a function of spindle speed, instantaneous DOC, rate of material removal, tool geometry, and material imbal- ance induced whirling. It is found that chatter can be eminent using one set of tool geometry while, at the same DOC, be sufficiently sup- pressed by employing tool inserts of different geometric parameters. Nonlinearity of tool structure is shown to have a dominant effect on tool vibration amplitude. High feed rate contributes to stability at high DOCs, thus indicating that feed rate is among the parameters that impact cutting stability.

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