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Generalized mechanics and dynamics of modulated turning
Journal of Materials Processing Technology ( IF 6.3 ) Pub Date : 2022-07-05 , DOI: 10.1016/j.jmatprotec.2022.117708
Bora Eren , Soohyun Nam , Burak Sencer

This paper presents a generalized cutting force and regenerative chatter stability prediction for the modulated turning (MT) process. Uncut chip thickness is modeled by considering current tool kinematics and undulated (previously generated) surface topography for any given modulation condition in the feed direction. It is found that chip formation is governed by the undulated surface generated in multiple past spindle rotations. Uncut chip thickness is computed analytically in the form of trigonometric functions, and cutting forces are predicted by making use of orthogonal cutting mechanics. Regenerative chatter stability of the process is also modelled. Analytical semi-discretization-based solution is developed to accurately predict the stability lobe diagrams (SLDs) of the MT process. Predicted stability lobes are validated through numerical time-domain simulations and experimentally via orthogonal (plunge) turning tests. It is found that as compared to conventional single-point continuous turning, regenerative stability of MT exhibits multiple (3) regenerative delay loops and long out-of-cut duration in-between tool engagement stabilizes the process to reach up to 2x higher stable widths/depths as compared to the conventional continuous turning.



中文翻译:

调制车削的广义力学和动力学

本文提出了调制车削 (MT) 过程的广义切削力和再生颤振稳定性预测。通过考虑当前刀具运动学和在进给方向上的任何给定调制条件下的起伏(先前生成的)表面形貌来模拟未切屑厚度。研究发现,切屑的形成是由在过去多次主轴旋转中产生的波状表面控制的。未切削的切屑厚度以三角函数的形式进行解析计算,并利用正交切削力学预测切削力。过程的再生颤振稳定性也被建模。开发了基于分析半离散化的解决方案,以准确预测 MT 过程的稳定叶图 (SLD)。预测的稳定性波瓣通过数值时域模拟和正交(切入)转向试验进行验证。结果发现,与传统的单点连续车削相比,MT 的再生稳定性表现出多 (3) 个再生延迟回路,并且刀具啮合之间的较长的失切持续时间使加工过程稳定,达到高达 2 倍的稳定宽度/深度与传统的连续车削相比。

更新日期:2022-07-05
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