Influence of flank face on the condition of chatter self-excitation during turning

Abstract

This paper addresses a modelling approach for cutting tool and workpiece material interaction with ploughing taken into account. In the proposed model the distributed contact on the flank face is replaced by a concentrated additional cutting edge characterised by two physical parameters and bringing about a new delay term into the dynamical system. It is shown that under monoharmonic excitation of the tool on the direction orthogonal to the cutting velocity, it is possible to isolate the effect of the flank face and observe experimentally its parameters. The influence of the ploughing on the instability boundaries of continuous cutting is investigated. An analytical expression is obtained for the effective linear damping coefficient due to ploughing and depending on the cutting velocity.

Multi-cutter turning process stability analysis

“…Cutting forces in axial direction for each cutter are accounted for by an analytical model based on a rational fraction expression [8,11]:…”

“…Multi-cutter turning is one of the ways to increase the productivity of turning process in manufacturing [1][2][3][4][5]. At certain conditions, the turning process involving constant chip thickness incurs dynamic instability [5][6][7][8]11]. The loss of stability and the onset of auto-oscillations may be sensitive to several phenomena, such as the regenerative cutting of the surface created by the previous tool pass, ploughing caused by the flank face interaction, workpiece flexibility, temperature-induced effects [8][9][10][11][12][13][14].…”

Automated block-by-block correction of milling parameters by means of numerical simulation

“…The software package 3DCUT [5,6,9], which was designed by the authors of this paper for modelling of the figurine-shaped compliant parts machining dynamics, was proposed to put in use to draw the diagrams of instantaneous values of cut-off thickness along the tool cutting edges. These diagrams are needed to calculate the value of the criterion for the feed optimization.…”

“…The issues of the cutting process modeling [1][2][3][4][5][6][7][8][9][10][11] and feed correction during milling have been examined in the papers of foreign and home authors.…”

Nonlinear Regenerative Dynamics Analysis of the Multicutter Turning Process

“…One of the methods of increasing the productivity of the turning process is the use of multiple cutter systems, in which the effective depth of cut in one pass can be increased, the cutting forces can be partially balanced (especially in the transversal direction, which is particularly important for thin-walled workpieces), cutting operations can be combined (e.g., raw and finishing), and the processing time can be substantially reduced. Several works have addressed multiple cutter turning systems in recent years [2,4,8,9,10,11,12,13,19,20].…”