On the Dynamics of High-Speed Milling with Long, Slender Endmills

Abstract

Tool deflections of high length-to-diameter ratio endmills are measured with capacitance probes during high-speed milling and compared with the predictions of regenerative chatter theory. Poincaré sectioning (once per revolution sampling) techniques are introduced as a new means of characterizing and identifying chatter. The regenerative chatter theory seems to accurately predict the stability of high-immersion slotting cuts; however, undesirable vibrations observed in partial immersion cuts seem inconsistent with existing theory. The practical utility of in-depth knowledge of the stability behaviour of long endmills is demonstrated by the high-speed machining of an example component using a dynamically tuned tool.