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Simulation of forced vibration in milling process considering gyroscopic moment and rotary inertia

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Prevention of resonance in vibration of cutting tool is essential for achieving high quality and efficiency of the milling process. The resonance causes the cutting tool to oscillate with great amplitude and increases cutting tool wear and production costs. Using a 3-D nonlinear dynamic model of the milling process including both structural and cutting force nonlinearities, gyroscopic moment, and rotary inertia, different types of resonances in milling process are investigated in this article. The cutting tool is modeled as a rotating clamped-free beam which is excited by cutting forces. Using the method of multiple scales, frequency response function of the system in primary and super harmonic resonances is obtained. Using this model, the influences of axial depth of cut, cutting tool diameter, cutting tool length, and the number of cutter teeth on the frequency response of the tool tip vibrations are studied. The results showed that increase of axial depth of cut increases the steady state vibration response of the tool tip in all resonance cases.

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Correspondence to Mohammad Mahdi Jalili.

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Jalili, M.M., Hesabi, J. & Abootorabi, M.M. Simulation of forced vibration in milling process considering gyroscopic moment and rotary inertia. Int J Adv Manuf Technol 89, 2821–2836 (2017). https://doi.org/10.1007/s00170-016-9618-9

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  • Milling process
  • Primary resonance
  • Super harmonic resonance
  • Nonlinear model
  • Method of multiple scales