Dynamic response of circular saw blade based on dynamic sawing force model in machining hard aluminum alloys

Carbide circular saw blades are indispensable tools extensively utilized in aerospace and transportation industries. However, modeling of sawing force and dynamic behavior of circular saw blades with large diameter-thickness ratio has rarely been reported. Hence, the aim of this study is to predict the scratches caused by saw tooth vibration on the sawing surface by proposing an axial vibration model for circular saw blades based on the dynamic sawing force. First, the dynamic undeformed chip thickness is established based on the sawtooth element movement method, which presents the circular saw blade geometry, sawing parameters, and so on. A novel dynamic sawing force model is built using this undeformed chip thickness. Then, the axial dynamic response is solved by the additional axial force introduced by the dynamic sawing force. Finally, sawing experiments were carried out, and the results confirmed the feasibility of the model.