Abstract
In this article, a new model of regenerative vibrations due to the deflection of the cutting tool in turning is proposed. The previous study reported chatter as a result of cutting a wavy surface of the previous cut. The proposed model takes into account cutting forces as the main factor of tool deflection. A cantilever beam model is used to establish a numerical model of the tool deflection. Three-dimensional finite element method is used to estimate the tool permissible deflection under the action of the cutting load. To analyze the system dynamic behavior, 1-degree-of-freedom model is used. MATLAB is used to compute the system time series from the initial value using fourth-order Runge–Kutta numerical integration. A straight hard turning with minimal fluid application experiment is used to obtain cutting forces under stable and chatter conditions. A single-point cutting tool made from high-speed steel is used for cutting. Experiment results showed that for the cutting parameters above 0.1mm/rev feed and [Formula: see text]mm depth of cut, the system develops fluctuations and higher chatter vibration frequency. Dynamic model vibration results showed that the cutting tool deflection induces chatter vibrations which transit from periodic, quasi-periodic, and chaotic type.
Highlights
Turning operation is one of the most effective machining processes for the manufacturing of metal and nonmetal components used in different industries
We observed that cutting tool deflection results in the complex dynamic behavior of the system because of nonlinear interaction between the tool and workpiece which leads to chatter vibrations
The permissible magnitude of the tool deflection under the action of the cutting load has been obtained by finite element analysis
Summary
Turning operation is one of the most effective machining processes for the manufacturing of metal and nonmetal components used in different industries. A cutting tool is fed into a rotating workpiece to generate an external or internal surface concentric with the axis of rotation. Turning is carried out using a lathe machine, one of the most versatile conventional machine tools. The cutting tool is held in on a translating carriage or turret or in the tailstock. The carriage or turret travels along the bedways parallel to the part axis (Z-axis) being machined. The motion perpendicular to the part axis is provided by the X-axis or a cross slide mounted on the carriage. The workpiece is mounted on a rotating spindle using a chuck, collet, faceplate, or a mandrel, or between pointed conical centers
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