ON STABILITY PREDICTION FOR LOW RADIAL IMMERSION MILLING

ABSTRACT

Stability boundaries for milling are predicted by the zeroth-order approximation (ZOA) and the semi-discretization (SD) methods. For high radial immersions, the methods predict similar stability boundaries. As radial immersion is decreased, the disagreement between the predictions of the two methods grows considerably. The most prominent difference is an additional type of instability predicted only by the SD method. The experiments confirm the predictions of the SD method. Three different types of tool motion are observed: periodic chatter-free, quasiperiodic chatter, and periodic chatter motion. Tool displacements recorded during each of the three motion types are analyzed.

Keywords:

• End Milling
• Stability Prediction

ACKNOWLEDGMENTS

JG gratefully acknowledges support of the Alexander von Humboldt Foundation from Germany. TI was supported by the Magyary Zoltán Postdoctoral Fellowship of Foundation for Hungarian Higher Education and Research, and together with GS, also by the Hungarian National Science Foundation under grant no. OTKA T043368.