Investigation of thermal effects on machining chatter based on FEM simulation of chip formation

In this paper, thermo mechanical finite element analysis of orthogonal machining process with a flexible tool is carried out to study the dynamic behaviour of the machining system and its stability against chatter vibration. By combining the simulation of chip formation in metal cutting with the dynamic phenomena leading to chatter development, the influence of various phenomena, including thermal effects resulting from friction and plastic deformations on the stability of the process are investigated. The novelty of this model is in its ability to evaluate the effect of temperature rise in the cutting zone on the stability of cutting process. Process stability is analyzed and compared for the systems with/without thermal effects. Results show that decreasing the width of cut and tool rake angle and increasing the cutting velocity lead to higher temperatures, which in turn leads to the more stable conditions.