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Numerical investigation of cutting stability and surface roughness in orthogonal milling

The vibrations produced by the chatter phenomenon are harmful for productivity in material removal machining. Some of the intolerable effects are: workpiece poor surface quality, tool wear, machine lifetime reduction. The flexibility of the cutting system favors vibrations especially when the cutting conditions are inconvenient. The flexibility is mainly linked to the cutting tool, which explains the consideration of the cutting tool as flexible in most of the analytical and numerical literature works. This work presents a numerical approach to investigate the orthogonal metal milling in order to study the chatter phenomenon effect on cutting stability and surface roughness. The proposed approach for numerical simulation uses the ABAQUS software, and includes a flexible tool on the immersion direction as well as on the feed direction. An explicit scheme and a Lagrangian formulation are retained, and the Johnson-Cook laws of behavior and damage are considered. The validation of the numerical results is conducted using experimental results.