Unstable cutting due to chatter vibrations is one of the most important problems during metal cutting operations. Chatter can be a limitation for productivity and surface quality in turning operations, especially when long and slender tools and parts are involved. In this study, an analytical stability method for turning process is presented. The model takes the cutting geometry into considerat...

This paper investigates the effect of displacement constraints on attenuation performance tuned mass dampers (TMDs) used in boring and turning applications. A simplified piecewise-smooth mechanical model is investigated through time domain simulations hybrid periodic orbit continuation, first under harmonic excitation, then regenerative cutting load. quasi-frequency response function derived fo...

To predict the milling stability accurately and efficiently, an improved numerical integration method (INIM) is proposed based on Lagrange interpolation scheme. First, dynamic model considering regenerative chatter can be described as a delay linear differential equation. The tooth passing period of cutter divided into free forced vibration stages. Then, stage equally discretized, INIMs are bui...

Chatter stability in milling can be improved significantly using variable pitch cutters. The pitch angles can be optimized for certain chatter frequency and spindle speed ranges using the analytical method presented in the first part of this two-part paper. In this part, the improvement of productivity and surface finish are demonstrated in three example applications. It is shown that chatter s...

Chatter is an instability phenomenon in machining processes which limits productivity and results in inferior workpiece quality, noise and rapid tool wear. The increasing demand for productivity in the manufacturing community motivates the development of an active control strategy to shape the chatter stability boundary of manufacturing processes. In this work a control methodology for the high...

& Stability boundaries for milling are predicted by the zeroth-order approximation (ZOA) and the semi-discretization (SD) methods. For high radial immersions, the methods predict similar stability boundaries. As radial immersion is decreased, the disagreement between the predictions of the two methods grows considerably. The most prominent difference is an additional type of instability predict...

Chatter has been recognized as major restriction for the increase in productivity of cold rolling processes, limiting the rolling speed for thin steel strips. It is shown that chatter has close relation with rolling conditions. So the main aim of this paper is to attain the optimum set points of rolling to achieve maximum rolling speed, preventing chatter to occur. Two combination methods were ...

In the fabrication process of thin-walled micro-parts, both micro-cutting tools and micro-parts have characteristics small size low stiffness. Therefore, regenerative chatter during machining cannot be ignored. The influence tool runout error actual trochoidal trajectories cutting edge on micro-milling forces should also considered comprehensively. this paper, in is first analysed, an instantan...

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