Abstract
The experimental determination of stability lobe diagrams (SLDs) in milling can be realized by either continuously varying the spindle speed or by varying the depth of cut. In this paper, a method for combining both these methods along with an online chatter detection algorithm is proposed for efficient determination of SLDs. To accomplish this, communication between the machine control and chatter detection algorithm is established, and the machine axes are controlled to change the spindle speed or depth of cut. The efficiency of the proposed method is analyzed in this paper.
Highlights
Material removal rate (MRR) significantly determines the financial viability of a cutting process
A method for combining both these methods along with an online chatter detection algorithm is proposed for efficient determination of SLDs
These simulation models of the dynamic milling process are valid for tools with large numbers of teeth and high radial immersion, they still suffer from several disadvantages
Summary
Material removal rate (MRR) significantly determines the financial viability of a cutting process. In the case of conventional as well as high-speed milling, MRR is mainly limited by the maximum achievable depth of cut without process instability or regenerative chatter. The critical depth of cut during milling can be either estimated by a simulation model or established experimentally for a given combination of machine, workpiece, and tool. Several assumption and simplifications regarding material properties, force characteristics, and dynamic behavior are necessary to create a dynamic milling model, which introduces inaccuracies. Despite these simplifications and assumptions, an analytical solution for the stability boundary still requires certain expertise and cannot be readily implemented in the industry
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