On the use of modal works of cutting forces to optimize machining conditions in the presence of vibrations

Abstract

The use of Virtual Machining models may be a valuable approach in the designing stage of a machining operation as long as the models are sufficiently accurate. When vibration risks are suspected, stability analysis approaches to predict regenerative chatter phenomena are generally used. However, although these approaches, when applicable, allow efficient numerical optimization of the process around an operating point, they often require other strong assumptions such as neglecting transient phenomena or oversimplifying kinematics. On the other hand, time domain approaches with detailed matter removal modelling allow to monitor the continuous evolution of cutting conditions and represent various phenomena that the models can reproduce (regenerative chatter, forced vibrations, non-linear behaviours). The amount of data produced is, however, considerable and often costly to analyse. It may therefore be interesting to deduce, from these data, scalar indicators allowing easier and more relevant analysis of the simulation results. In this work, the modal work of the cutting forces upon the workpiece vibratory displacements is proposed as an indicator to discriminate different tool paths. A one degree of freedom theoretical problem and a face milling operation on extruded aluminum profiles extracted from automotive structural part are used to explain and show the relevance of such indicator.