Prediction of Surface Quality Based on the Non-Linear Vibrations in Orthogonal Cutting Process: Time Domain Modeling

Kibbou Kibbou,Dellagi Dellagi,Majdouline Majdouline,Moufki Moufki

doi:10.3390/jmmp3030053

Abstract

This work presents an analysis of relationships between the non-linear vibrations in machining and the machined surface quality from an analytical model based on a predictive machining theory. In order to examine the influences of tool oscillations, several non-linear mechanisms were considered. Additionally, to solve the non-linear problem, a new computational strategy was developed. The resolution algorithm significantly reduces the computational times and makes the iterative approach more stable. In the present approach, the coupling between the tool oscillations and (i) the regenerative effect due to the variation of the uncut chip thickness between two successive passes and/or when the tool leaves the work (i.e., the tool disengagement from the cut), (ii) the friction conditions at the tool–chip interface, and (iii) the tool rake angle was considered. A parametric study was presented. The correlation between the surface quality, the cutting speed, the tool rake angle, and the friction coefficient was analyzed. The results show that, during tool vibrations, the arithmetic mean deviation of the waviness profile is highly non-linear with respect to the cutting conditions, and the model can be useful for selecting optimal cutting conditions.

Highlights

In machining processes, the tool self-excited vibrations represent a significant limiting factor for manufacturing process optimization and machining efficiency
In order to examine the influence of the dynamic cutting process on the machined surface quality, different non-linear mechanisms resulting from the relative movement between the tool and the chip must be considered
This paper presents an analysis of relationships between the non-linear vibrations in machining and the machined surface quality from an analytical model based on a predictive machining theory

Summary

Introduction

The tool self-excited vibrations represent a significant limiting factor for manufacturing process optimization and machining efficiency. To analyze the coupling between the machining operation and vibrations, several theoretical studies of chatter stability were developed using linear analysis of the stationary cutting under regenerative conditions. For high-speed milling, the authors of Reference [28] developed a dynamic model to analyze the coupling between machined surface roughness and process conditions in face milling. To estimate the surface roughness parameters during finish cylindrical milling, the authors of Reference [29] developed an analytical model including tool dynamic deflections and static errors of the machine–tool-holder–tool system. In order to examine the influence of the dynamic cutting process on the machined surface quality, different non-linear mechanisms resulting from the relative movement between the tool and the chip must be considered. The correlation between the surface quality, the cutting speed, the tool rake angle, and the friction coefficient was analyzed

Analytical Modeling

Results and Discussion

Conclusions