Machining Stability and Machine Tool Dynamics

Machining is a common manufacturing process in industry due to its high flexibility and ability to produce parts which excellent quality. The productivity and quality in machining operations can be limited by several process constraints one of which is the self-excited chatter vibrations. Under certain conditions, the process may become unstable yielding oscillations with high amplitudes which result in poor surface finish and damage to the cutting tool, part and the machine tool itself. Stability analysis of the dynamic cutting process can be used to determine chatter-free machining conditions with high material removal rate. Since chatter is a result of the dynamic interactions between the process and the structures both cutting and machine tool dynamics are important elements of the stability analysis. In this paper, methods developed for stability analysis of cutting processes and machine tool dynamics will be presented. Implications of these methods in the selection of process parameters and machine tool design will be also discussed with example applications.