Cutting Force Modeling And Analysis In Axial Contour CNC Turning

With the wider use of CNC machine tools, machining centers, FMS and the develop of some special fields such as aerospace, biomedical, automotive, and other industries are developing rapidly, contour parts of increasingly extensive and important, such as motor vehicle wheel, the pulley, camshaft, braking, etc. and NC machining of the workpiece contour method is a good surface quality, high efficiency, has become a trend. the process of cutting machine vibration of the impact of the workpiece machining quality, but also affected the machine and tool life, The noise pollution will also work environment, even when serious machining process is not over yet. To ensure the necessary processing workpiece quality, and sometimes have to reduce the amount of cutting. causing the machine tool cutting performance and full play, severely limiting production machining efficiency. So the process of turning the dynamic stability of increasingly urgent.But several challenges such as large cutting forces, excessive part deflections, localized vibrations, and difficulties in chip-management, are encountered while machining contoured parts. These challenges are caused due to the effects of the workpiece geometric variations on the metal removal mechanics. The geometric variations in contoured workpieces cause variations in the uncut chip-geometry and effective tool-angles and consequently produce variations in the cutting forces and process stability along the toolpath. Therefore, the simple turning process-planning (cutting condition and tooling selection) strategies prove to be inadequate for contouring applications.In this paper, an equivalent chip-area formulation has been developed, and is used to model the dynamic machining forces, and a mechanistic force model and an investigation of the stability variations for contour turning is presented.The stability solution developed here is capable of accommodating the effects of cutting conditions (axial and radial feed, depth of cut, and spindle speed) tooling geometry (lead angle and corner radius) and structural parameters (the mass stiffness, damping ratio and orientation of the dominant mode).