1. Machining modeling Goals for part production by machining
Dimensionally accurate part
Desired surface finish
No chatter (unstable behavior)
Acceptable tool life
Dynamometer testing
Surface location error (SLE)
Force model
Stability
Stable
Frequency domain SLE
Time domain simulation
Tool wear
Frequency domain stability
Modal fitting
Frequency response function (FRF)
Chatter
Receptance coupling modeling
Modal testing

2. Research opportunities
Predictions and experiments differ due to uncertainties.
What are some opportunities for improvement in machining modeling?
Typically empirical. Can be described using Johnson-Cook constitutive model (or similar).
𝐹 𝑡 = 𝑘 𝑡𝑐 𝑏ℎ 𝑖 + 𝑘 𝑡𝑒 𝑏
Composition  microstructure  tool geometry  force
Dynamometer testing
Surface location error (SLE)
Force model
Stability
Frequency domain SLE
Time domain simulation
Tool wear
Frequency domain stability
Empirical. Tool life often described by power law (Taylor 1906).
𝐶= 𝑣 𝑝 𝑓 𝑡 𝑞 𝑇
Composition  microstructure  tool geometry  wear rate
Modal fitting
Frequency response function (FRF)
Damping is empirical.
𝑚 𝑥 𝑥 𝑡 + 𝑐 𝑥 𝑥 𝑡 + 𝑘 𝑥 𝑥 𝑡 = 𝐹 𝑥 𝑡
Material properties  geometry  interface  energy dissipation
Receptance coupling modeling
Modal testing