The Prediction of Chatter Stability in Hard Turning
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Despite a large demand from industry, a realistic chatter modeling for hard turning has not been available due to the complexity of the problem, which is mainly caused by flank wear and nonlinearity in hard turning. This thesis attempts to develop chatter models for predicting chatter stability conditions in hard turning with the considerations of the effects of flank wear and nonlinearity. First, a linear model is developed by introducing non-uniform load distribution on a tool tip to account for the flank wear effect. Second, a nonlinear model is developed by further incorporating nonlinearity in the structure and cutting force. Third, stability analysis based on the root locus method and the describing function approach is conducted to determine a critical stability parameter. Fourth, to validate the models, a series of experiment is carried out to determine the stability limits as well as certain characteristic parameters for facing and straight turning. From these, it is shown that the nonlinear model provides more accurate predictions than the linear model, especially in the high-speed range. Furthermore, the stabilizing effect due to flank wear is confirmed through a series of experiments. Fifth, to fully account for the validity of linear and nonlinear models, an empirical model is proposed to fit in with the experimental stability limits in the full range of cutting speed. The proposed linear and nonlinear chatter models will help to improve the productivity in many manufacturing processes. In addition, chatter experimental data will be useful to develop other chatter models in hard turning.