Metal cutting is a widely used method of producing manufactured products. The technology of metal cutting has advanced considerably along with new materials, computers, and sensors. This new edition treats the scientific principles of metal cutting and their practical application to manufacturing problems. It begins with metal cutting mechanics, principles of vibration, and experimental modal analysis applied to solving shop floor problems. Notable is the in-depth coverage of chatter vibrations, a problem experienced daily by manufacturing engineers. The essential topics of programming, design, and automation of CNC (computer numerical control) machine tools, NC (numerical control) programming, and CAD/CAM technology are discussed. The text also covers the selection of drive actuators, feedback sensors, modeling and control of feed drives, the design of real time trajectory generation and interpolation algorithms, and CNC-oriented error analysis in detail. Each chapter includes examples drawn from industry, design projects, and homework problems. This book is ideal for advanced undergraduate and graduate students, as well as practicing engineers.

Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design

Analytical Prediction of Stability Lobes in Milling

Chatter is a self-excited vibration that can occur during machining operations and become a common limitation to productivity and part quality. For this reason, it has been a topic of industrial and academic interest in the manufacturing sector for many years. A great deal of research has been carried out since the late 1950s to solve the chatter problem. Researchers have studied how to detect, identify, avoid, prevent, reduce, control, or suppress chatter. This paper reviews the state of research on the chatter problem and classifies the existing methods developed to ensure stable cutting into those that use the lobbing effect, out-of-process or in-process, and those that, passively or actively, modify the system behaviour.

Chatter in machining processes: A review

Chatter Stability of Metal Cutting and Grinding

A new analytical method of chatter stability prediction in milling is presented. A general formulation for the dynamic milling system is developed by modeling the cutter and workpiece as multi-degree-of-freedom structures. The dynamic interaction between the milling cutter and workpiece is modeled considering the varying dynamics in the axial direction. The dynamic milling forces are governed by a system of periodic differential equations with delay whose stability analysis leads to an analytical relation for chatter stability limit in milling. The model can be used to determine the chatter free axial and radial depth of cuts without resorting to time domain simulations.

Stephen Albert Tobias

Papers

Machine Tool Vibration

A Theory of Nonlinear Regenerative Chatter

Theory of finite amplitude machine tool instability

The relation between the static and the dynamic cutting of metals

Machine tool vibration research