Mode-CoupledRegenerativeMachineToolVibrationsTams.PDFVIP

Mode-Coupled Regenerative Machine Tool Vibrations 1 2 Tamás Kalmár-Nagy , Francis C. Moon 1United Technologies Research Center, 411 Silver Lane, East Hartford, CT 06108 2Sibley School of Mechanical and Aerospace Engineering Cornell University, Ithaca, NY 14853, USA Abstract In this paper a new 3 degree-of-freedom lumped-parameter model for machine tool vibrations is developed and analyzed. One mode is shown to be stable and decoupled from the other two, and thus the stability of the system can be determined by analyzing these two modes . It is shown that this mode-coupled nonconservative cutting tool model including the regenerative e¤ect (time delay) can produce an instability criteria that admits low-level or zero chip thickness chatter. 1 Introduction One of the unsolved problems of metal cutting is the existence of low-level, random-looking (maybe chaotic) vibrations (or pre-chatter dynamics, see Johnson and Moon [17]). Some possible sources of this vibration are the elasto-plastic separation of the chip from the workpiece and the stick-slip friction of the chip over the tool. Recent papers of Davies and Burns [9], Wiercigroch and Krivtsov [43], Wiercigroch and Budak [41] and Moon and Kalmár-Nagy [27] have addressed some of these issues. Numerous researchers investigated single degree-of- freedom regenerative tool models (Tobias [39], Hanna and Tobias [13], Shi and Tobias [34], Fofana [11], Johnson [18], Nayfeh et al. [28], Kalmár-Nagy et al. [20], Stépán [36], Kalmár-Nagy [21], Stone and Campbell [38], Stépán et al. [37]). Even though the classical model (Tobias [39]) with nonlinear cutting force is quite successful in predicting the onset of chatter (Kalmár-Nagy et al., [19]),