Review of potential advantages and pitfalls of numerical simulation of self-excited vibrations

Machining stability is one of the most important factors influencing the geometrical and dimensional accuracy of the machined parts. Regenerative chatter is a major limitation to the productivity and quality of machining operations due to poor surface finish and faster tool wear. In general there are two methods of stability analysis: solution of differential equations of the system in frequency domain or numerical simulation in time domain. Fast and easy calculations in the frequency domain are possible using a simplified linear model of cutting process. Important limitations of these methods are difficult or impossible considering of changes of dynamic cutting force coefficients and dynamic characteristic of a process. Numerical simulation has not these limitations and regards many specific phenomena of the cutting processes, therefore it is often used in the stability analysis. The paper presents main advantages of numerical simulation, which differentiates it from the analytical solutions, as well as some inevitable difficulties and limitations