Chatter vibration and surface location error prediction for helical end mills

Abstract

This paper describes a new theoretical model for the cutting forces of a helical end mill. A specific advantage for the presented model is the convenience in implementing the developed expressions for vibration prediction. Specifically, the presented force model is used to predict cutting forces with a Fourier series expansion, to predict surface location error with a Harmonic Balance approach, and to simultaneously predict surface location error and chatter vibration with an updated temporal finite element analysis. The developed analyses are compared and validated through comparisons with prior works.