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After shifting coordinates to eliminate constant force Fh
0
and transformation
to canonical form
Crucial argument: Boundary of stability separates a regime of exponentially
damped oscillations from a regime of exponentially growing oscillations
At boundary of stability: Oscillations are neither growing nor damped
Consequence: We can assume solution in the form ) exp( ) ( t i X t x =
[ ]
( ) [ ] ( )
( ) [ ]
2
0
2
0
2
2
2
0
0
2
0
2
1 2
4 1
1 ) exp( 2 1
+
=
=
|
|
\
|
+
|
|
\
|
M
T i i
Minimal critical value of the feedback parameter: At
Below this parameter, no instability can occur at any frequency. In physical
terms, this means that there is a minimal chip width below which cutting is
absolutely stable irrespective of spindle speed.
( ) 2 1
2
0
+ =
) 1 ( 2
min
+ =
Relation between spindle speed and oscillation frequency:
Solution of this transcendental equation produces a stability diagram
of critical cutting parameter vs. critical spindle speed:
( )
( )
2
0
0
1
1
2
tan 2 ) 1 2 (
+ =
n T
Spindle speed f [
0
/2]
C
u
t
t
i
n
g
p
a
r
a
m
e
t
e
r
m
i
n
Diagram has the shape of a sequence of lobes. Interpretation of the lobe
diagram:
Instability occurs first where the spindle speed (revolutions per second)
times the number of oscillations on the workpiece surface (the lobe
number)matches the natural frequency of the tool oscillation (in Hertz)
At higher cutting parameters the instability boundaries expand and
ultimately merge.
For each cutting parameter there is a highest spindle speed where
the cutting operation becomes absolutely stable.
Summary: Sources of vibration in machining operations
Forced vibration due to rotating unbalances in machinery -> vibration
amplitude varies weakly with machine speed, vibration amplitude is
independent of cutting parameters, vibration frequency = rotation speed
of machine
Self-excited vibration -> vibration amplitude varies strongly with spindle
speed and chip width (vibrations emerge suddenly upon a small
change of parameters), vibration frequency = natural frequency of tool
oscillations
Consequences: Poor surface finish, reduction of tool lifetime, damage to
workpiece and machinery.
Diagnostics: Measure frequency and amplitude of vibration while varying
spindle speed and chip width.
Mitigation: If forced vibration: move rotation speed out of resonance.
If self-excited: fine tune rotation speed, reduce chip width.