Stability of high frequency machining vibration by extended chatter model

An extended chatter model was proposed in a previous paper [1], which explains the onset of machining chatter at frequencies as high as 10,000 Hz in fine boring operation. The model consists of an equation of energy equilibrium, including two sources of energy supply and other two sources of energy dissipation. The sources of energy supply are by the regeneration and X–Y looping of the tool tip, and the sources of energy dissipation are by the structural damping and the cutting process damping. esent study applies the energy equilibrium equation for predicting the stability borderline in terms of cutting condition. At the cutting condition above the stability borderline where the chatter should occur, some parameters are further predicted by computation to characterize the vibration of the tool tip. The transition from the borderline to the condition above the borderline has been evaluated by the predictive calculation of the time phase between X and Y vibration displacements, the inner to outer modulation phase lag, and the percentage share by mechanisms of the energy supply and dissipation. ty of the prediction in terms of borderline width of cut, and X to Y amplitude ratio are confirmed by comparison with experimental measurements obtained in cutting tests.