Effect of cutting conditions and tool geometry on process damping in machining

Process damping can be a significant source of enhanced stability in metal cutting operations especially at low cutting speeds. However, it is usually ignored in stability analysis since models and methods on prediction and identification of process damping are limited. In this study, the effects of cutting conditions and tool geometry on process stability in turning and milling are investigated through simulations. The previously developed models by the authors are used in simulations to demonstrate conditions for enhanced process damping, and thus chatter stability. Some representative cases are presented and verified by experimental data and conclusions are derived. Cutting conditions and tool geometry for enhanced chatter stability due to increased process damping are presented.

► Effects of cutting conditions and tool geometry on process damping are examined.
► Effective parameters on process damping are identified by modeling and experiments.
► Process damping coefficients can be generalized considering the contact geometry.
► Models can be used to design cutting tools for enhanced process damping.
► High radial depth or number of teeth may not lower stability with process damping.