Analytical Prediction of Chatter Stability in Milling—Part II: Application of the General Formulation to Common Milling Systems

Abstract

The general formulation for the milling chatter prediction developed in Part I of the paper is applied to common milling systems. Three cases are considered: a workpiece with single-degree-of-freedom, a face milling cutter with two-degree-of-freedom, and peripheral milling of a cantilevered thin web. The general milling stability formulation is further simplified for the less complicated models. For each case, an analytical expression which explicitly relate the chatter limit to the milling conditions and tool-workpiece dynamics are derived. The analytical predictions are compared with numerical and time domain solutions proposed by previous research. It is shown that the proposed method can accurately predict the chatter limits in milling and thus eliminates the time consuming numerical solutions.

A simulated investigation on the machining instability and dynamic surface generation

“…The machining instability coined here is a new generalized concept, which includes all phenomena making the machining process departure from what it should be. For instance, a variety of disturbances affect the machining system such as such as self-excited vibration [10], thermomechanical oscillations in material flow [11], Feed drive hysteresis [12] etc., but the most important one is self-excited vibrations resulted from dynamic instability of the overall machine-tool/machining-process system [5]. However, sometimes the machining process is carried out with a relative vibration between the workpiece and the cutting tool especially in heavy cutting and rough machining in order to obtain high material removal rates.…”

“…Taking the turning process as a case study, the modelling outcome will be the real tool path. After getting the real tool path on the workpiece, the intersection points of the sequence tool path are calculated by the following equation: (5) Where r and H are the projection on plane XZ and height vector of the intersection points of the sequence tool path, respectively. ti is the index for the tool tip position in the tangential force direction.…”

“…Altintas et al have undertaken a lot of research on milling processes with stability analysis [4,5]. They looked at the processes with many kinds of cutters and dropped the feed term from the expression for the instantaneous chip thickness prior to the stability analysis.…”

Improvement of chatter stability in boring operations with passive vibration absorbers

“…In the 1990s Budak and Altintas [11,12] developed several works for milling, modeling the cutting tool as a two-degree-offreedom linear system. The instantaneous chip thickness, tool geometry, and tooth number were considered for the estimation of the cutting force.…”

Fuzzy stability analysis of regenerative chatter in milling

“…Previous workers [14] have shown that the data used in the transformation method can be used to determine the sensitivity of the response to the different fuzzy inputs. Further work could investigate the application of this approach to the chatter 20 stability problem.…”