Determination of Critical Depth of Cut for Stable Machining Operations
Juraev M.A. Alikulov D.E. Kardassinov S.M. Tuyboyov O.V.
2025Abylkas Saginov Karaganda Technical University
Material and Mechanical Engineering Technology
2025#2025Issue 43 - 9 pp.
This study presents a hybrid experimental-analytical methodology for the accurate determination of the critical depth of cut-the maximum axial engagement below which chatter-free machining is sustained. The proposed framework integrates stability lobe theory, frequency response function (FRF) modeling, and real-time signal acquisition using accelerometers and dynamometers. Machining trials were conducted on CNC systems using AISI 1045 steel and various carbide tool configurations, including standard and micro-grooved inserts. Experimental results showed a strong correlation between analytically predicted and observed critical depth thresholds, with deviations reduced to ±5% through in-process FRF updates. Micro-grooved inserts increased critical depth margins by 10-15%, while surface roughness and cutting force RMS data clearly indicated the transition to instability beyond the threshold. Stability lobe diagrams constructed using FRFs effectively identified chatter-free regions across spindle speeds, supporting precise parameter selection. Statistical analysis confirmed the method’s repeatability, with standard deviations below 0.12 mm and 95% confidence intervals. The results validate the proposed framework as a robust tool for real-time stability prediction and chatter suppression, contributing to the development of adaptive, intelligent machining systems.
chatter stability , CNC machining , critical depth of cut , frequency response function , stability lobe diagram , tool wear , vibration analysis
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Almalyk branch of Tashkent state technical university, Almalyk, Uzbekistan
Tashkent state technical university, Tashkent, Uzbekistan
Kazakh Automobile and Road Institute, Kazakhstan
Technology Transfer Office, Tashkent, Uzbekistan
Almalyk branch of Tashkent state technical university
Tashkent state technical university
Kazakh Automobile and Road Institute
Technology Transfer Office
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