International Journal of Machine Tools & Manufacture最新文献

{"title":"Stable tongues induced by milling tool runout","authors":"David Hajdu ,&nbsp;Oier Franco ,&nbsp;Markel Sanz-Calle ,&nbsp;Giovanni Totis ,&nbsp;Jokin Munoa ,&nbsp;Gabor Stepan ,&nbsp;Zoltan Dombovari","doi":"10.1016/j.ijmachtools.2025.104258","DOIUrl":"10.1016/j.ijmachtools.2025.104258","url":null,"abstract":"<div><div>High material removal rates and performances are required for modern milling operations, which may trigger self-excited chatter vibrations. Such undesired vibrations cause unacceptable machined surface quality and premature deterioration of the cutting tool. After many decades of research and successful industrial solutions to this problem, some unexpected phenomena still arise, which put in doubt the effectiveness of well-known chatter theories and of the associated predictive numerical methods. Specifically, runout is a typically ignored consequence of inaccurate fixing of the tool, which has essential impact on the actual cutter-workpiece engagement and on the machined surface quality. The unequal engagement of cutter teeth change the dynamical behavior radically and prevent the application of classical simplifications in the modeling of milling processes. Moreover, in addition to the kinematically different teeth cycle-paths, the coexisting forced vibrations induce early fly-over effects of cutting edges creating new stability boundaries close to the resonant oscillations. This paper presents the underlying principles of this experienced phenomenon related to tool runout and its stabilization effect on chatter vibrations. Focusing on conventional milling cutters, the paper breaks with the widely held assumption that forced vibration has negligible effect on stability in the presence of tool runout. Initial laboratory experiments validate this tool irregularity induced phenomenon and industrial tests demonstrate the technical relevance of the results.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"206 ","pages":"Article 104258"},"PeriodicalIF":14.0,"publicationDate":"2025-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143548738","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Micro-zone cutting temperature measurement using a nitrogen-extracted boron and hydrogen co-doped diamond tool for ultra-precision machining","authors":"Shiquan Liu,&nbsp;Liang An,&nbsp;Hui Li,&nbsp;Kaiyang Xia,&nbsp;Mao Peng,&nbsp;Zhongwei Li,&nbsp;Bing-Feng Ju,&nbsp;Yuan-Liu Chen","doi":"10.1016/j.ijmachtools.2024.104244","DOIUrl":"10.1016/j.ijmachtools.2024.104244","url":null,"abstract":"<div><div>Accurate measurement of the cutting temperature is essential for monitoring the cutting state and ensuring a reliable cutting process. In ultra-precision machining, directly measuring the temperature in the micro/nano-scale cutting zones poses substantial challenges. In this study, a nitrogen-extracted boron and hydrogen co-doped diamond tool was proposed. By transitioning into a p-type semiconductor, the diamond tool manifests heat-sensitive characteristics, enabling to sense the cutting temperature. The inherent orientation-dependent behaviour of boron doping in diamond tools, particularly notable in the (100) orientation, was suppressed through removal of nitrogen from the lattice. The lattice distortions induced by heavy boron doping after nitrogen removal in (111)-oriented diamond were significantly mitigated by co-doping with boron and hydrogen. This approach enhanced the crystal quality and semiconductor electrical properties of the diamond tools, which are crucial for accurate measurement of the cutting temperature. Compared with boron-doped diamond tools, the nitrogen-extracted boron and hydrogen co-doped diamond tool exhibited superior sensitivity and an extended range of temperature sensing. The diamond tool was employed for cutting temperature measurements during the micro-scale depth-graded turning of copper and titanium alloys, as well as the nano-scale progressive scratching of silicon. Experiments demonstrated the tool's capabilities for in-process monitoring of cutting states in micro zones, along with high-sensitivity detection of micro/nano-scale surface morphologies and characteristics during ultra-precision machining. The innovation of temperature-sensing diamond tools not only achieves accurate measurement of temperature in micro/nano-scale cutting zones during ultra-precision machining, but also provides an effective approach for in-process state characterisation for advanced manufacturing.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"205 ","pages":"Article 104244"},"PeriodicalIF":14.0,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142929192","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Laser additive manufacturing of multimaterials with hierarchical interlocking interface via a flexible scraper-based method","authors":"Linqing Liu ,&nbsp;Di Wang ,&nbsp;Tianyu Wang ,&nbsp;Changjun Han ,&nbsp;Yang Li ,&nbsp;Hua Tan ,&nbsp;Wei Zhou ,&nbsp;Xingchen Yan ,&nbsp;Liming Lei ,&nbsp;Yongqiang Yang","doi":"10.1016/j.ijmachtools.2024.104236","DOIUrl":"10.1016/j.ijmachtools.2024.104236","url":null,"abstract":"<div><div>Superalloy/copper structures are promising for application in rocket combustion chambers and can integrate the high strength of superalloys and the high thermal conductivity of copper in a single component to improve performance and work efficiency. The natural hierarchical interlocking structure can provide inspiration for the interface design of metallic multimaterial structures to resolve or minimise the critical issue of interfacial bonding reliability arising from the distinct physical properties of materials (thermal expansivity, thermal conductivity, <em>etc.</em>). In this study, IN718/CuCrZr multimaterial structures with hierarchical interlocking interfaces were designed and manufactured using laser powder bed fusion (LPBF) via a flexible scraper-based method. The evolution of microstructure at the interface and mechanical properties were investigated. The thermomechanical behaviour during the LPBF process, interfacial bonding mechanisms, and deformation mechanisms were discussed. Compared to printing CuCrZr before IN718, printing IN718 before CuCrZr was a promising printing sequence for reducing the stress concentration and lack-of-fusion defects, and promoting material intermixing at the interface. A hierarchical interlocking interface design can promote material intermixing and grain refinement at the interface. In addition, the hierarchical interlocking interface design can improve the stress distribution and deflect the fracture path at the interface, which helps increase energy dissipation and enhance interfacial bonding. Three-point flexural test results show that the ultimate flexural strength of the N1 samples was increased by 15 % compared to the N0 samples. This study demonstrates the feasibility of changing the interfacial stress distribution and deformation behaviour of LPBF-processed metallic multimaterial parts through a hierarchical interlocking interface design, which may provide new ideas and methods for the development of multimaterial parts with high interfacial bonding strength and reliability.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"205 ","pages":"Article 104236"},"PeriodicalIF":14.0,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142793449","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Electrical discharge-mechanical hybrid drilling of micro-holes in carbon fibre-reinforced polymers","authors":"Yijin Zhao,&nbsp;Xiaodong Yang,&nbsp;Yong Lu,&nbsp;Xiaoming Duan","doi":"10.1016/j.ijmachtools.2024.104243","DOIUrl":"10.1016/j.ijmachtools.2024.104243","url":null,"abstract":"<div><div>The machining of deep micro-holes in carbon fibre-reinforced polymers (CFRP) components exhibits a significantly increased demand in the industry. However, it is difficult to machine CFRP deep micro-holes using conventional mechanical drilling and non-conventional processes individually because of the anisotropic and inhomogeneous characteristics of CFRP. To address this problem, an electrical discharge-mechanical hybrid drilling method was proposed in this study. In this method, a specialized servo control strategy was employed to effectively utilize the electrical discharge machining and mechanical drilling, based on the distinct difference in electrical conductivity between the carbon fibre and the resin in CFRP. This effectively resolved the challenges posed by the high hardness of the carbon fibre for mechanical drilling and the non-conductivity of the resin for EDM, taking advantage of both EDM and mechanical drilling. High-speed photography, processing debris analysis, discharge state monitoring, and finite element simulation were performed to investigate the machining process and material removal mechanism of electrical discharge-mechanical hybrid drilling. The results showed that most of the carbon fibre and resin were individually removed by EDM and mechanical drilling, respectively. However, in the interfacial region between the carbon fibre and resin, both mechanical drilling and EDM occur simultaneously. The heat generated during the EDM of carbon fibre also leads to the thermal decomposition and vaporization of the resin in proximity to the carbon fibre. Furthermore, deep micro-holes machining with a diameter of 330 μm and a depth-to-diameter ratio of 15.1 was performed on CFRP component to validate the advantages of the proposed hybrid drilling method. Compared with EDM, the proposed hybrid drilling method exhibited a 29.1 % increase in efficiency, 56.25 % reduction in taper, and 54.32 % reduction in the heat-affected zone. These outcomes demonstrate that the electrical discharge-mechanical hybrid drilling holds great potential for machining high-quality micro-holes on advanced multilayer composites with anisotropic and inhomogeneous properties.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"205 ","pages":"Article 104243"},"PeriodicalIF":14.0,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142901911","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"How does ultrasonic cutting affect the macroscopic deformation and microstructure evolution of fibre-reinforced titanium matrix composites?","authors":"Liyu Wang ,&nbsp;Xiaoxing Gao ,&nbsp;Qiaosheng Feng ,&nbsp;Xinlong Guo ,&nbsp;Zhen Li ,&nbsp;Wenzhao An ,&nbsp;Weiwei Xu ,&nbsp;Qilin Li ,&nbsp;Songmei Yuan","doi":"10.1016/j.ijmachtools.2024.104245","DOIUrl":"10.1016/j.ijmachtools.2024.104245","url":null,"abstract":"<div><div>Continuous silicon carbide (SiC) fibre-reinforced titanium (Ti) matrix composites (SiC_f/Ti) possess exceptional properties, making them promising for aerospace applications. Continuous SiC fibres significantly enhance the axial tensile strength of SiC_f/Ti compared to traditional Ti alloys. To utilise this material fully, its axial dimensions are fixed during manufacturing, but the outer Ti matrix layer must be thinned to meet structural accuracy requirements. Thinning often leads to interfacial cracking and fibre breakage owing to machining stress, which presents a major challenge in manufacturing. The deformation mechanism during thinning is unclear and the lack of low-stress thinning methods significantly limits the potential applications of SiC_f/Ti. This study investigates the macroscopic deformation and microstructural evolution of SiC_f/Ti under ultrasonic cutting (UC) through orthogonal experiments. Compared with conventional cutting (CC), UC reduces cutting force by 20 % and surface residual stress by 60 %, while increasing subsurface residual stress and nano-hardness. The acoustic softening effect in UC reduces cutting force and surface stress, while high-frequency stress waves elevate subsurface stress. Digital image correlation (DIC) analysis reveals that the combined effects of loading and unloading cycles during UC produce an elastic recovery strain, reducing the overall deformation in SiC_f/Ti during machining. Additionally, UC promotes grain refinement in the outer Ti layer of SiC_f/Ti and induces a stress concentration at the α-Ti and β-Ti interface, facilitating the transformation of α-Ti to β-Ti. The presence of SiC fibres amplifies the effects of the ultrasonic energy, accelerating dislocation diffusion and annihilation, promoting dynamic recrystallisation, and reducing the dislocation density between the fibres. Moreover, UC homogenises and realigns the stress field at the SiC_f/Ti interface, making the composition and structure of the interface more uniform and reducing interfacial damage. This study provides theoretical and practical insights into low-stress thinning, paving the way for broader applications of SiC_f/Ti in advanced structural components.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"205 ","pages":"Article 104245"},"PeriodicalIF":14.0,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142929193","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Super-resolution laser machining","authors":"Jiaxu Huang,&nbsp;Kang Xu,&nbsp;Shaolin Xu","doi":"10.1016/j.ijmachtools.2025.104246","DOIUrl":"10.1016/j.ijmachtools.2025.104246","url":null,"abstract":"<div><div>Super-resolution laser machining represents a cutting-edge advancement in precision manufacturing, striving to approach or even exceed the optical diffraction limit to produce structures with exceptionally fine feature sizes, minimal heat-affected zones, and intricate freeform patterns. The present paper provides an overview of two principal approaches developed to achieve super-resolution: one is reducing the diffraction limit through the adoption of shorter laser wavelengths or advanced focusing techniques, and the other is surpassing the diffraction limit by advanced manipulation of the laser and its interactions with materials. With a deep investigation of the principles of these super-resolution laser machining methods, the review mainly explores the recent advancements in laser characteristics manipulation, materials innovation, and the integration of adaptive optics, high-speed laser scanning equipment, and feedback systems, all of which aim at enhancing machining resolution and broadening its applicability. Focusing on research frontiers and industrial applications, we also critically discussed future directions, potential problems, and possible solutions to smaller structure manufacturing regarding the light source, optical system, laser-matter interactions, and the surface evaluation methods. It also highlights the prospects for super-resolution laser machining, emphasizing its potential to transform precision manufacturing across industries.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"205 ","pages":"Article 104246"},"PeriodicalIF":14.0,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143136846","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Combining in situ synchrotron X-ray imaging and multiphysics simulation to reveal pore formation dynamics in laser welding of copper","authors":"T. Florian ,&nbsp;K. Schricker ,&nbsp;C. Zenz ,&nbsp;A. Otto ,&nbsp;L. Schmidt ,&nbsp;C. Diegel ,&nbsp;H. Friedmann ,&nbsp;M. Seibold ,&nbsp;P. Hellwig ,&nbsp;F. Fröhlich ,&nbsp;F. Nagel ,&nbsp;P. Kallage ,&nbsp;M. Buttazzoni ,&nbsp;A. Rack ,&nbsp;H. Requardt ,&nbsp;Y. Chen ,&nbsp;J.P. Bergmann","doi":"10.1016/j.ijmachtools.2024.104224","DOIUrl":"10.1016/j.ijmachtools.2024.104224","url":null,"abstract":"<div><div>Laser beam welding has emerged as a powerful tool for manufacturing copper components in electrical vehicles, electronic devices or energy storage, owing to its rapid processing capabilities. Nonetheless, the material’s high thermal conductivity and low absorption of infrared light can introduce process instabilities, resulting in defects such as pores. This study employs a hybrid approach that combines in situ synchrotron X-ray imaging with compressible multiphysics process simulation to elucidate pore-forming mechanisms during laser beam welding of copper. High-speed synchrotron X-ray imaging with an acquisition rate of 20,000 images/second facilitates the identification of relevant process regimes concerning pore formation during laser beam welding of copper with a wavelength of 1070 nm. Furthermore, in situ observations with high temporal and spatial resolution present a unique database for extensive validation of a multi-physics process simulation based on welding processes using different concentric intensity distributions. These validated simulation results enable thorough comprehension of process-related pore formation based on the interaction between keyhole, melt pool and resulting flow field. The findings show that pore formation is driven by four different mechanisms: bulging, spiking, upwelling waves at the keyhole rear wall and melt pool ejections. The synergy of high-speed synchrotron X-ray imaging and multi-physics modeling provides a fundamental understanding of the chronological sequence of events leading to process-related pore formation during laser beam welding of copper.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"204 ","pages":"Article 104224"},"PeriodicalIF":14.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142663709","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Understanding thermal-mechanical variations and resulting joint integrity of pressure-controlled linear friction welding of thin-steel sheets","authors":"Rishabh Shotri ,&nbsp;Takuya Miura ,&nbsp;Peihao Geng ,&nbsp;Yoshiaki Morisada ,&nbsp;Kohsaku Ushioda ,&nbsp;Hidetoshi Fujii","doi":"10.1016/j.ijmachtools.2024.104235","DOIUrl":"10.1016/j.ijmachtools.2024.104235","url":null,"abstract":"<div><div>Linear friction welding is a solid-state joining technology that bonds materials via friction heating and plastic deformation. This process is being extensively researched for welding metallic sheets with different dimensions; however, it involves difficulties in joining thin cross-sections due to extensive misalignment and unsteady plastic extrusion of softened materials at interfaces. This study introduces novel efforts for joining thin cross-sections through pressure-controlled oscillations and displacements, facilitating localized plastic flow essential for high-strength solid-state bond formation. This method is rare, and the results reveal base metal fractures in tensile-tested welded joints of 2 mm thick S45C steel sheets. The interfacial yielding at specific temperatures is obtained by applying pressure corresponding to the temperature-dependent strength of the material. Accordingly, the welding is attempted using a hydraulic-based clamping system designed to accommodate large sheet lengths while allowing precise control of the interface pressure and temperature to facilitate controlled material plastic discharge. However, the requisite joint evolution tracking remains infeasible due to the intricate weld designs and is instead uncovered through novel numerical investigations. Modeling simultaneous oscillations and forging displacement while maintaining pressure depicted the kinetics of continual interfacial deformation. The transient fluctuations in plastic stress and temperature increments distinguish the stages of forging under different conditions. The computed temperature vs. plastic strain and the measured change in interfacial microstructures from martensite to dynamically recrystallized very fine ferrite with fragmented small cementite explain the lower temperature welding for an increase in applied pressure, enhancing the understanding of linear friction welding of thin steel sections for industrial applications.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"204 ","pages":"Article 104235"},"PeriodicalIF":14.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142757383","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Investigation of three-dimensional forces during additive friction stir deposition — How could force signals reveal the deposition quality?","authors":"Yiming Huang ,&nbsp;Qi Liu ,&nbsp;Kaiyue Zhang ,&nbsp;Mingyu Li ,&nbsp;Tianhao Yang ,&nbsp;Lijun Yang ,&nbsp;Lei Cui","doi":"10.1016/j.ijmachtools.2024.104234","DOIUrl":"10.1016/j.ijmachtools.2024.104234","url":null,"abstract":"<div><div>Additive friction stir deposition (AFSD) is a solid-phase forming technology based on microzone forging, which is essentially a force-driven additive manufacturing process. This work focuses on the effects of the AFSD parameters on the force signals and forming quality, which is highly important for optimizing the process parameters and controlling the forming quality. By analyzing the force features in the time‒frequency domain, the evolution mechanism of three-dimensional forces during AFSD was explored. A 3D scanner, scanning electron microscope (SEM) and electron backscatter diffraction (EBSD) were used to clarify the surface morphology and microstructures of the deposition layers. It was found that deposition defects were accompanied by a lack of plasticization or nonuniform deformation between the advancing side (AS) and the retreating side (RS). Moreover, the relationships among the process parameters, three-dimensional forces and deposition quality were investigated. It is proved that force signal can effectively reflect the deposition quality. A comprehensive prediction model based on three-dimensional force features was developed, achieving an accurate prediction of deposition quality. Furthermore, this work demonstrated the feasibility of AFSD quality control on the basis of force signals. The currently employed control strategies can be further extended to address the AFSD of large components in the future.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"204 ","pages":"Article 104234"},"PeriodicalIF":14.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142705452","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Towards a differentiated understanding of process damping and the introduction of process stiffening effects","authors":"Florian Wöste ,&nbsp;Timo Platt ,&nbsp;Jonas Baumann ,&nbsp;Dirk Biermann ,&nbsp;Petra Wiederkehr","doi":"10.1016/j.ijmachtools.2024.104233","DOIUrl":"10.1016/j.ijmachtools.2024.104233","url":null,"abstract":"<div><div>The effect of process damping is an effective means to favorably influence the stability of machining processes. Its occurrence depends on the dynamic contact between the flank face of the tool and the workpiece surface. To specifically investigate the fundamentals of process damping effects in the context of process stabilization, different configurations of modified cutting tools were prepared and applied for this contribution. These modifications consisted of tools with conventional and functionally structured flank face chamfers and were expected to cause distinctly different interaction characteristics. While the use of conventional flank face chamfers was expected to cause a rather significant share of elastic deformation of workpiece material, the application of surface structures was intended to provoke an increased degree of dissipative, i.e., process damping effects due to plastic deformation of workpiece material. By conducting orthogonal cutting experiments using a sensor-integrated analogy setup, milling tests as well as representative simulation approaches, the fundamental interrelations of the dynamic interaction between the workpiece surface and tools with both conventional and structured chamfers were characterized. It was observed that a conventional flank face chamfer in contact with the workpiece surface causes predominantly elastic deformations of the workpiece material due to a relatively large contact area, resulting in distributed, low local contact stresses below the yield stress. These elastic deformations led to a temporary stiffening effect on the dynamic system significantly affecting its dynamic behavior, e.g., in form of increased vibration frequencies. In contrast, surface structures led to an increased share of plastic deformation due to concentrated contact stresses at the structure tips and, thus, to dissipative, i.e., damping effects. Based on the experimental and simulation-based results presented as part of this contribution, which are consistent with observations made in previous studies, a differentiated consideration of process damping as one of five methods for process stabilization is discussed. In this context, the introduction of process stiffening in addition to process damping as a stabilizing process inherent contact phenomenon is proposed for future consideration.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"204 ","pages":"Article 104233"},"PeriodicalIF":14.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142696897","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}