Stability analysis of milling chatter with tool-workpiece multiple interactions and velocity effects

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Journal of Vibration and Shock ›› 2021, Vol. 40 ›› Issue (17) : 14-24.

JI Yongjian1, WANG Xibin2, LIU Zhibing2, WANG Hongjun1

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Abstract

Here, to study effects of tool-workpiece multiple interactions and velocity effect on milling chatter stability, a milling dynamic model including tool-workpiece multiple interactions and velocity effect was established.Influence laws of regeneration effect, process damping, tool structure modal coupling and velocity effect on milling chatter stability under the condition of no tool axis inclination angle were clarified, and effects of tool-workpiece interaction and velocity effect on milling stability under different radial immersion ratios were studied.The results showed that compared with the milling dynamic model only considering regenerative effect, chatter region in stability lobe diagram changes obviously when simultaneously considering regenerative effect, process damping and tool structure modal coupling; when the spindle’s rotating speed is lower, tool-workpiece multiple interaction effects are the main factor affecting milling chatter stability, influence of speed effect on limit cutting depth can be negligible; with increase in spindle rotating speed, influence of speed effect on limit cutting depth gradually increases, and stable region in stability lobe diagram gradually decreases; within a certain range, with increase in wear land of milling cutter flank, milling limit cutting depth gradually increases; when spindle speed is constant, process damping affects milling stability more obviously under the condition of relatively smaller radial immersion ratio; compared with traditional dynamic model, the established milling dynamic model here can more reliably predict actual milling state.

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milling / chatter stability / tool-workpiece interactions / velocity effect / stability lobe diagram

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JI Yongjian, WANG Xibin, LIU Zhibing, WANG Hongjun. Stability analysis of milling chatter with tool-workpiece multiple interactions and velocity effects[J]. Journal of Vibration and Shock, 2021, 40(17): 14-24

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