Abstract
High speed Hardware-In-the-Loop (HIL) system was built including real spindle subjected to emulated high resolution state dependent cutting force of milling operation. Regenerative chatter is the main limitation of milling operations that may go unstable with frequency locked to the spindle speed producing flip-type instabilities. Its appearance is a unique phenomenon which is undeniable proof of the correct HIL representation of real milling operations. Its dependency on the tool pitch is presented experimentally and compared to an analytical approximation. The flip-type loss of stability is highly relevant for finishing operations, where interrupted cutting forces with flip harmonics often arise.
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