Modeling and Emulation of 3d Dither Stability in Orthogonal Turn-Milling

Abstract

Aiming at 4-axial orthogonal turn-milling by end mill, its theoretical 3d model for stable range of dither was put forward on the basis of its cutting principle by using analytical method. Based on modal trial, the stable range leaf figure of end mill’s dither in 4-axial turn-milling with eccentricity was simulated and analyzed. The results show that besides geometrical shape of mill, material of workpiece and frequency response function of machine-tool’s structure etc that can produce dither in 4-axial turn-milling, the rotating speed of mill and cutting depth are also related to dither. In trial of 4-axial turn-milling by end mill, the results of cutting force spectrum analysis show that: cutting is stable and un-dither when frequency of cutter tooth cutting-in plays leading role in force spectrum. Dither is produced when modal frequency of system plays leading role in force spectrum, the measured value of cutting force and surface roughness are also higher than those in the condition of un-dither. Thus the theoretical model and results of emulation can predict stability of end mill’s dither in 4-axial orthogonal turn-milling with eccentricity correctly and can provide theoretical guidance for surface quality and processing efficiency of workpiece.