Determination of Critical Depth of Cut for Stable Machining Operations

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

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