The effects of workpiece deflection and motor features on quality of machining process - Nonlinear vibrations analysis

The present research aims at the establishment of a novel methodology to analyze the responses of a nonlinear machining system subjected to cutting forces excitations. For a systematic analysis, a nonlinear dynamic cutting system is developed that includes the main factors affecting vibration in machining. A new cutting vibration model is established to reflect the realistic vibrations of both the workpiece and the cutting toot of a lathe-type machining system. Vibrations of the workpiece and the cutting tool in a turning system are investigated on the basis of a coupled cutting vibration system established in the research. The effects of the workpiece deflection on the vibration of the machining system are considered. Moreover, the influences of nonlinear electrical features of the machining system's drive motor on the cutting vibration response are also considered in quantifying the nonlinear cutting force and the relative displacements between the workpiece and cutting tool. A set of numerical investigations of the behavior of the nonlinear cutting system is also carried out with implementation of the proposed model.