Chatter suppression is essential for achieving high precision and surface quality in machining processes. In this paper, a control strategy is presented for chatter suppression in cutting process in the presence of tool wear and parameter uncertainties. A single-degree-of-freedom model of a turning process in the orthogonal cutting configuration is used to set up the nonlinear delay differentia...

Metal cutting is a severe plastic deformation process involving large strains, high strain rates, and high temperatures. Conventional analysis of the chip formation process is based on bulk material deformation disregarding the inhomogeneous nature of the material microstructure. A series of orthogonal cutting tests of AISI 1045 and 1144 steel were conducted which yielded similar process charac...

The process of cutting is analysed in fracture mechanics terms with a view to quantifying the various parameters involved. The model used is that of orthogonal cutting with a wedge removing a layer of material or chip. The behaviour of the chip is governed by its thickness and for large radii of curvature the chip is elastic and smooth cutting occurs. For smaller thicknesses, there is a transit...

This paper introduces a dynamic cutting force model for turning of slender workpieces, as well as experimental results related to the frequency response of the workpiece in turning. The model is based on a flexible workpiece and rigid machine tool, and a workpiece displacement dependent cutting force. The model is described and studied theoretically as well as experimentally. The experimental s...

We have analyzed vibrations generated in an orthogonal cutting process. Using a simple one degree of freedom model of the regenerative cutting we have observed the complex behaviour of the system. In presence of a shaped cutting surface, the nonlinear interaction between the tool and a workpiece leads the to chatter vibrations of periodic, quasi-periodic or chaotic type depending on system para...

This research outlines the Taguchi optimization methodology, which is applied to optimize cutting parameters in drilling of glass fiber reinforced composite (GFRC) material. Analysis of variance (ANOVA) is used to study the effect of process parameters on machining process. This procedure eliminates the need for repeated experiments, time and conserves the material by the conventional procedure...

* Corresponding author – [email protected] Tel: 414-229-4126 Fax:414-229-6958 ABSTRACT Understanding the tribological aspects of machining processes is essential for increasing the dimensional accuracy and surface integrity of products. In the present investigation, orthogonal metal cutting simulations were performed using an explicit finite-element code, LS-DYNA. In the simulations, a rigid stee...