Investigations of Process Damping Forces in Metal Cutting

TL;DR

This study uses finite element simulations to analyze process damping forces in metal cutting, revealing how tool geometry and cutting speed influence damping behavior and chatter stability.

Contribution

It introduces a detailed finite element approach to quantify process damping forces and their dependence on tool length and cutting parameters.

Findings

Damping force from crushing is proportional to cutting speed for short tools.

Damping force is inversely proportional to cutting speed for long tools.

Wavelength of surface waviness affects force oscillations and damping behavior.

Abstract

Using finite element software developed for metal cutting by Third Wave Systems we investigate the forces involved in chatter, a self-sustained oscillation of the cutting tool. The phenomena is decomposed into a vibrating tool cutting a flat surface work piece, and motionless tool cutting a work piece with a wavy surface. While cutting the wavy surface, the shearplane was seen to oscillate in advance of the oscillation of the depth of cut, as were the cutting, thrust, and shear plane forces. The vibrating tool was used to investigate process damping through the interaction of the relief face of the tool and the workpiece. Crushing forces are isolated and compared to the contact length between the tool and workpiece. We found that the wavelength dependence of the forces depended on the relative size of the wavelength to the length of the relief face of the tool. The results indicate that the damping force from crushing will be proportional to the cutting speed for short tools, and inversely proportional for long tools.