Simulative Parameterization of Dead Time Variable Rotation Speed Behavior to Improve Process Stability in High Performance Cutting

A common method to improve process stability in machining operations with geometrically defined cutting edges is the variation of dead time behavior of tooth engagement, which is the most responsible influence on regenerative force amplification. In this paper a simulation model in time domain is presented, considering the effect of active and passive spindle speed variation (SSV) with regard to the calculation of process stability. The simulation approaches have been validated by experimental cutting tests on a longitudinal turning process in C45N. Beside the improvement of simulation technique, this paper points out the potential of process stabilization by high rates of SSV, even though variation frequencies and amplitudes nowadays are still limited by the drive power of machine tool systems. Additionally, a theoretical approach is presented describing the influence of process and SSV parameterization on the chip thickness modulation as well as the achievable improvement of process stability.