Analytical modeling of chatter stability using multi-dimensional approach

Machining is one of the most common manufacturing processes in industry due to its high flexibility and ability to produce parts which excellent quality. Chatter, a type of self excited vibrations arising in metal cutting operations, is a major limitation in machining resulting in poor quality and reduced productivity. Under certain conditions, the cutting process may become unstable yielding oscillations with high amplitudes and cutting forces. Stability analysis of the dynamic cutting process can be used to determine chatter-free machining conditions with high material removal rate. Usually, one dimensional models are used for stability analysis of machining. However, based on the geometry of the actual machining process, multi-directions would have to be used for accurate modeling of the process dynamics and the stability. In this presentation, multi directional models for turning and milling processes are presented. The effects of multi directional process mechanics on the stability are demonstrated by applications. (© 2008 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim)