Metal Cutting Dynamics With Reference to Primary Chatter

Identification of metal cutting dynamics is important for predicting the occurrence of chatter. An experimental investigation was conducted to study the relationship between the oscillations in the undeformed chip thickness and the oscillations in the thrust and cutting forces in orthogonal cutting during wave producing or a simulation of primary chatter. The relationship exhibits hysterisis which changes from passive to active as the frequency is increased; it is also a function of the amplitude of oscillations in the undeformed chip thickness. The objective was to relate the experimental results to the development of a nonlinear theory of analysis of chatter as a limit cycle oscillation by the describing function method.