Tuning of tool dynamics for increased stability of parallel (simultaneous) turning processes

Parallel (simultaneous) turning operations make use of more than one cutting tool acting on a common workpiece offering potential for higher productivity. However, dynamic interaction between the tools and workpiece and resulting chatter vibrations may create quality problems on machined surfaces. In order to determine chatter free cutting process parameters, stability models can be employed. In this paper, stability of parallel turning processes is formulated in frequency and time domain for two different parallel turning cases. Predictions of frequency and time domain methods demonstrated reasonable agreement with each other. In addition, the predicted stability limits are also verified experimentally. Simulation and experimental results show multi regional stability diagrams which can be used to select most favorable set of process parameters for higher stable material removal rates. In addition to parameter selection, developed models can be used to determine the best natural frequency ratio of tools resulting in the highest stable depth of cuts. It is concluded that the most stable operations are obtained when natural frequency of the tools are slightly off each other and worst stability occurs when the natural frequency of the tools are exactly the same. (C) 2015 Elsevier Ltd. All rights reserved.