Chapter 7 - Modeling and analysis of high speed milling process stability for industry applications

Abstract

A novel approach has been developed for the prediction of stability of milling operation. The stability has been predicted using stability lobe diagram (SLD), which was developed using process-based mathematical models. A coupled approach for dynamic receptance at different parts of machine tool has been adopted instead of obtaining receptance directly at the tool tip. This helps to generalize the present model for various milling tools. A dynamic signature of a typical VMC in terms of receptance has been captured at the tool holder using a onetime experimental modal test. The receptance functions at the fluted portion of the milling tool were obtained using Timoshenko beam theory. Using a MATLAB-based code, both these receptance were coupled to obtain the receptance at tool tip [frequency response function (FRF)]. The tool-tip FRF along with the cutting force coefficients, which were obtained using strain in deformed chip (SDC) model, has been further used for the development of the SLD. Unlike the existing approaches, the present approach avoids need of extensive experimental setup and numerical software prior development of a typical SLD. The present approach suits the machine tool production industry, wherein the receptance at clamped tool holder can be obtained by the machine builder prior to dispatch of the machine. In this way, SLD can easily be obtained by an unskilled operator feeding basic data about the milling tool (diameter, material, flutes, overhang, etc.), properties of workpiece, and the machining parameters (speed, feed, and depth of cut) to the model.