Identification and modeling of process damping in turning and milling using a new approach

Process damping can be a significant source of increased stability in machining particularly at low cutting speeds. However, it is usually ignored in chatter analysis as there is no model available to estimate process damping coefficients. In this study, a practical identification and modeling method is presented where process damping coefficients are obtained from chatter tests. The method is generalized by determining the indentation force coefficient responsible for the process damping through energy analysis. This coefficient is then used for process damping and the stability limit prediction in different cases, and predictions are verified by time domain simulations and experimental results. (C) 2010 CIRP.