Machining chatter simulation in multi-axis milling using graphical method

Abstract

In this work, a computer graphics approach is developed for time-domain simulation of chatter in multi-axis milling. The new chatter simulation method is based on the local adaptive depth buffer method of Roth, Ismail, and Bedi [ Mechanistic modelling of the milling process using an adaptive depth buffer, CAD 35 (4) (2003) 1287–1303;Mechanistic modelling of the milling process using complex tool geometry, Journal of Advanced Manufacturing Technology 25 (1–2) (2005) 140–144] that was originally developed to calculate the cutting forces for a rigid tool. In the current work, the dynamic characteristics at the tool tip as well as the regeneration mechanism are accounted for. Implementation details of the proposed method are given. Limitations of the graphical method imposed by the pixel size in relationship to the vibration amplitude and frequency are discussed. The graphical chatter simulation approach is shown to agree with the traditional numerical simulation method. It is also experimentally verified in one dimension as well as simultaneous three-axis machining. In the three-axis test, the tool/workpiece engagement varied along the tool path.