MetalCuttingDynamics

Metalcuttingisoneofthemostcommonlyusedmethodsofproducingthefinalshapeofmanufactured
products. Improved productivity is of essence for the industry in order to stay cost effective at a
competitive market. Vibrations in metal cutting constitute a large part in hindering the productivity
during machining. Excessive vibrations can lead to for example: accelerated tool wear, tool breakage,
poorsurfacefinishofthemachinedcomponentanddamagetothespindlebearings.Fastandaccurate
simulation routines and measurement methods for machining dynamics are very important in the
developmentofnewcuttingtools.

TheresearchiscarriedoutbyanindustrialPhDstudentworking50%withABSandvikCoromantand50%
with the structural analysis group, ensuring a close cooperation between industry and university. The
project focuses on methods for simulation and measurements of both linear and nonlinear dynamics
within metal cutting. Vibration damping is often a key factor in increasing productivity. Most damping
materials used today show some form of hysteretic behavior. Therefore, measuring and modeling of
nonlinearsystemswithhysteresisisanimportantpartoftheresearch(figure1).

Figure1Nonlinearhystereticdamperusedtoattenuatevibrationsinacuttingtool

Toaidtheproductdevelopment,computerbasedsimulationroutinesfornonlinearmechanicalsystems
incorporating both structural nonlinearities as well as nonlinear behavior originating from the cutting
process (for example: cutting forces and regenerative/selfexciting vibrations) are developed. These
simulationmodelsarecontinuouslyverifiedbyexperimentalmeasurements.Animportantfactorwhen
validating simulation models is reliable estimation of cutting forces. Correct measurements of cutting
forces can be difficult to obtain because of unwanted dynamic effects from the measurement setup
(forcedynamometerandworkpiece).Thesedynamiceffectscanleadtoerroneousresultsandmakeit
difficult to validate the model. A method to remove unwanted dynamic effects while still keeping
informationrelatedtothetruecuttingforceshavebeendevelopedandtestedwithgoodresults.

Examples of currently ongoing projects are, surface error prediction of a machined component using
dynamicsimulationsandoptimizationofdifferentialpitchcutters.

STAparticipant:
MartinMagnevall