Forced Vibration in Cutting Process considering the Nonlinear Curvature and Inertia of a Rotating Composite Cutter Bar

Forced vibration of the cutting system with a three-dimensional composite cutter bar is investigated. The composite cutter bar is simplified as a rotating cantilever shaft which is subjected to a cutting force including regenerative delay effects and harmonic exciting items. The nonlinear curvature and inertia of the cutter bar are taken into account based on inextensible assumption. The effects of the moment of inertia, gyroscopic effect, and internal and external damping are also considered, but shear deformation is neglected. Equation of motion is derived based on Hamiltonʼs extended principle and discretized by the Galerkin method. The analytical solutions of the steady-state response of the cutting system are constructed by using the method of multiple scales. The response of the cutting system is studied for primary and superharmonic resonances. The effects of length-to-diameter ratio, damping ratio, cutting force coefficients, ply angle, rotating speed, and internal and external damping are investigated. The results show that nonlinear curvature and inertia imposed a significant effect on the dynamic behavior of the cutting process. The equivalent nonlinearity of the cutting system shows hard spring characteristics. Multiple solutions and jumping phenomenon of typical Duffing system are found in forced response curves.