Study of the System of Forces Acting on the Cutter‐Oscillator Under Conditions of Turning With Vibration

This paper investigates the forces acting on a cutter‐oscillator during free longitudinal orthogonal turning under regenerative self‐oscillation conditions. The cutter‐oscillator had single degree of freedom in the direction of cutting thickness variation, while the workpiece was rigid and made of AISI 1045 steel. Cutting parameters such as cutting speed, feed rate, and depth of cut, as well as the cutter‐oscillator’s additional mass, were varied. Two main groups of forces influencing the cutter‐oscillator were identified. The first group consists of cutting forces generated during chip formation and friction between the tool edge, chip, and cutting surface. These forces depend on the equilibrium between the shear plane and the tool’s contact surfaces. The second group arises from the dynamic behavior of the cutter‐oscillator and includes elastic, inertial, and damping forces. These are governed by the cutter‐oscillator’s mass and its response to cutting loads. An important feature of the system is the mutual interaction between these force groups, forming feedback loops that complicate analysis and control. Under regenerative self‐oscillations, the cutter‐oscillator’s deflections are affected by a combination of forces whose individual contributions cannot be isolated. As a result, conventional dynamometers, which have their own elastic properties, are unsuitable for capturing the true dynamics of the cutting process in such conditions. Cutter‐oscillators, by contrast, provide a more accurate representation of the cutting forces under self‐oscillation. The oscillogram of the cutter edge deflection serves as a reliable and reproducible indicator of both static and dynamic cutting conditions. This approach aids in better understanding of the process mechanics, contributes to the optimization of cutting parameters, and enhances overall manufacturing efficiency.