Analysis of the cutting tool on a lathe

Abstract

We use a systematic approach combining a path-following scheme, the method of multiple scales, the method of harmonic balance, Floquet theory, and numerical simulations to investigate the local and global dynamics and stability of cutting tool on a lathe due to the regenerative mechanism. First, we use the method of multiple scales to determine the normal form of the Hopf bifurcation at all of the stability boundaries and calculate the limit cycles generated by the bifurcation. Then, we use a combination of a path-following scheme and the method of harmonic balance to continue the branch of generated limit cycles. Thus, we calculate small- and large-amplitude limit cycles and ascertain their stability using Floquet theory. We validate these results using numerical simulations. Then, we search for isolated branches of large-amplitude solutions coexisting with the linearly stable trivial solution. We use all of the results to generate bifurcation diagrams consisting of multiple large-amplitude stable and unstable branches of limit cycles coexisting with the trivial response, indicating three regions of operation, as in the experimental observations. Then, we investigate bifurcation control using cubic-velocity feedback and show that the unconditionally stable region can be expanded at the expense of the conditionally stable region.