Stability Analysis and Nonlinear Chatter Prediction for Grinding a Slender Cylindrical Part

Abstract

A cylindrical plunge grinding process was modeled to investigate nonlinear regenerative chatter vibration. The rotating workpiece was a slender Euler–Bernoulli beam, and the grinding wheel was a rigid body moving towards the workpiece at a very low feed speed. A numerical method was proposed to provide the critical boundaries for chatter-free grinding. It was demonstrated that the intersection set surrounded by these critical boundaries was the chatter-free region for the considered parameters. When these parameters were outside of the chatter-free region, the stable grinding process underwent a supercritical Hopf bifurcation, resulting in the loss of the chatter-free behavior and the emergence of periodic chatter motions. Then, the periodic motions of both the grinding wheel and the workpiece were predicted analytically using the method of multiple scales, showing the effect of the regenerative force on the grinding process. We demonstrated that the analytical prediction was valid since it agreed with the numerical simulation. The results showed that there exist three kinds of nonlinear chatter motion, with different amplitudes and mode frequencies.