Machining Dynamics in Manufacturing

Abstract

Machining dynamics has been a critical academic and industrial discipline to determine a chatter-free cutting condition as well as to provide an insight into the vibration-resistant design of a machining system. This article presents the introduction, the modeling of machining dynamics in frequency and time domain, the simulation examples, and the application of machining dynamics into industries. The advantage of the frequency-domain solution is to rapidly generate stability lobes over the wide range of spindle speed and cutting depths and avoid computationally costly numerical solutions at the expense of ignoring the nonlinearities in comparison to the time-domain solutions. The time-domain model allows prediction of cutting forces, torque, and vibrations during machining, which is essential in planning the operations without overloading the tool, machine, and workpiece for a given set of cutting conditions. The time-domain simulation estimates the physics of the processes and allows the analysis of time-varying parameters, by incorporating the nonlinearities caused by material behavior, and tool geometry variations along the cutting edge. Both models can provide a map of chatter-free cutting conditions and a fundamental guide for process planners. Engineers can use the simulations to perform the analysis of various tool geometry, cutter-part engagement, and cutting conditions and avoid chatter vibrations. Finally, this article shows the actual application of the models into machining industries.