Use of finite element structural models in analyzing machine tool chatter

Abstract

It is widely accepted and well-documented that regenerative machine tool chatter is due to system instability. It is also well-known that machining system stability depends on both structural parameters and cutting process parameters. This paper focuses on the use of structural finite element (FE) models in the stability analysis of turning operations. The method presented allows for inclusion of both cutting tool and workpiece flexibility in the analysis. A structural model representing the machine tool system is created using the commercial FE code, ANSYS. This structural model can include practically any degree of detail desired. The structural model is then imported into a stand-alone FORTRAN program, which incorporates a cutting process model, and calculates the lobed borderline of stability. Numerical examples are provided.