An improved semi-analytical approach for modeling of process damping in orthogonal cutting considering cutting edge radius

Abstract

Process damping generated between the tool flank face and the wavy finish workpiece surface has a non-negligible effect on cutting dynamics and chatter stability, especially at low cutting speeds, resulting in higher stability limits. In modeling of process damping, the calculation of extruded volume is one of the most critical challenges, especially in machining with honed tools due to the complex and time-variable contact condition between the arc cutting edge and the finite amplitude wave surface. In this study, a semi-analytical method with high computational efficiency is proposed to calculate the extruded volume in cutting with honed tools. Based on this method, we construct the stability lobes under the condition of finite vibration amplitude accurately and efficiently, which overcomes the limitation of analytical methods based on the assumption of small amplitude vibrations and the low computational efficiency of numerical method. The predicted cutting stability is verified against both the experimental results and the time-domain simulation results.