Frictional chatter in orthogonal metal cutting

A comprehensive study of the frictional chatter occurring during metal-cutt ing process is given. A general mathematical model of the machine-tool-cutt ing process is established, and then a high-accuracy numerical algorithm is developed. Next, a two-degree-of-freedom model of orthogonal metal cutting is examined. Then stochastic properties of the material being cut are intr oduced to reflect variations in the workpiece properties, in particular, in the cutting resistance. Nonlinear dynamics techniques, such as constructin g bifurcation diagrams and Poincare maps, are employed to ascertain dynamic s responses for both the deterministic and the stochastic model. Untypical routes to chaos and unusual topology of Poincare cross-sections are observe d. The conducted analysis has provided some practical design recommendation s. Finally, occurrence of chatter was investigated analytically.