Analytical prediction of part dynamics for machining stability analysis

Abstract

An analytical procedure is developed to predict workpiece dynamics in a complete machining cycle in order to obtain frequency response functions (FRF) which are needed in chatter stability analyses. For this purpose, a structural modification method which is an efficient tool for updating FRFs is used. The removed mass by machining is considered as a structural modification in order to determine the FRFs at different stages of the process. The method is implemented in a computer code and demonstrated on different geometries. The predictions are compared and verified by FEA. Predicted FRFs are used in chatter stability analyses, and the effect of part dynamics on stability is studied. Different cutting strategies are compared for increased chatter free material removal rates considering part dynamics.