Abstract
In this article, the dynamic modelling of machining process for high aspect ratio workpiece is presented considering the tool-workpiece compliance. The geometric surface of high aspect ratio workpiece is digitized and the dynamic interaction between cutting tool and workpiece is calculated in time domain. The transfer function from both cutting tool and workpiece is integrated with directional coefficients derived from forces and dynamic uncut chip thickness equations. The integrated time domain model considers three directional vibrations with consideration of workpiece and tooling vibration modes. Since workpiece movement continuously changes the dynamic uncut chip thickness in conjunction with tool movement, the workpiece surface nodes need to be continually updated for the prediction of the regenerative chatter. Especially the small diameter of workpiece may cause the dynamic shift in conjunction with cutting conditions. Traditional frequency domain models with simplified directional coefficients have limitations in the prediction of machining stability for high aspect ratio workpiece due to the nonlinear factors in directional coefficients. Finally, the predictions from the time domain model are compared with the experimental results.
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