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Chatter Stability Prediction for Deep-Cavity Turning of a Bent-Blade Cutter
Xiaojuan Wang1, Qinghua Song1,2, Zhanqiang Liu1,2
1Key Laboratory of High Efficiency and Clean Mechanical Manufacture, Ministry of Education, School of Mechanical Engineering, Shandong University, Jinan 250061, China.
Sensors (Basel, Switzerland)
|January 23, 2024
Summary
This study models bent-blade cutter dynamics, incorporating bending-torsion vibrations to predict chatter. The findings help optimize cutting parameters for stable machining of deep-cavity parts.
Area of Science:
- Mechanical Engineering
- Manufacturing Processes
- Vibration Analysis
Background:
- Bent-blade cutters are crucial for deep-cavity parts like turbine discs.
- Existing chatter models neglect bending-torsion coupling and complex geometry, limiting their application.
- Understanding the dynamics of bent-blade cutters is essential for process stability.
Purpose of the Study:
- To investigate the dynamic behavior of bent-blade cutters during the turning process.
- To develop a dynamic model that accounts for regenerative chatter, bending, and torsional vibrations.
- To predict chatter stability and identify factors influencing machining vibration.
Main Methods:
- A dynamic model for bent-blade cutters was developed, incorporating regenerative chatter.
- Extended Timoshenko Beam Element (E-TBM) theory and Finite Element Method (FEM) were used.
- Coupling of bending-torsional vibrations and dynamic cutting forces were modeled along the turning path.
Main Results:
- The study theoretically analyzed vibration characteristics and derived the dynamical governing equation.
- Chatter stability was predicted considering the combined effects of bending and torsion.
- Experimental validation confirmed the model's accuracy and efficiency.
Conclusions:
- The developed model accurately predicts chatter stability in bent-blade cutter turning.
- The research provides insights into the influence of cutting parameters on machining stability.
- Optimizing cutting parameters based on this model can suppress vibration and enhance process stability.
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