Analysis of Tension Effect on Chatter Stability in Machining

This paper presents an analysis of the effect of tension on machining stability. It studies the mechanism of a self-excited vibration process by applying a tension force in the axial direction in a turning operation. This research investigates the tension effect on machining stability and develops a comprehensive model for the simulation of stability resulting from the axial tension force in machining, particularly for those applications in cutting long, slender, or thin materials. In addition, a new tension-fixturing technology is introduced to maximize stability and minimize undesirable chatter vibration in machining. The research can lead to a better understanding of stability and control of the cutting processes. It also can improve the traditional clamping method and provide important information in the design of the machine tool system, as well as in the planning, optimization, and production control for cutting processes. Following the theoretical analysis, an experimental study on chatter boundary illustrates the tension effect on machining stability. A comparison between the predicted and experimentally measured stability boundary, over a range of cutting conditions, shows favorable agreement.