Abstract
High-speed milling is a cost and time effective process, which becomes more popular nowadays. It especially available at milling of thin-walled structures of airfoil components. Manufacturer often faced with problem of producing thin-walled parts due to vibration and stability lobes theory in a lot of cases does not allow to avoid this problem by choosing the appropriate cutting conditions. In practice cutting condition for milling of thin walled detail is usually obtained by experimental way. In this paper authors present main differences of thin-walled end milling from classical end milling and show features of thin-walled end milling process and aspects, which effect on quality of surface finish. The aim of the paper is to validate that at high speed thin-walled end milling not only chatter is the reason of unstable cutting condition. Evaluation of stability, obtained by experimental tests, was compared with stability lobe diagram.
Highlights
A collaborative motion of a cutting tool and a workpiece in cutting processes leads to self-excited vibrations, called chatter
The basic principles of chatter theory have been developed by Tobias [1] and Tlusty [2], who studied the interaction of the dynamics of the machine tool structure with the dynamics of the cutting process
In fig 3, stability lobe diagram obtained by taking into account classical theory is shown
Summary
A collaborative motion of a cutting tool and a workpiece in cutting processes leads to self-excited vibrations, called chatter. The basic principles of chatter theory have been developed by Tobias [1] and Tlusty [2], who studied the interaction of the dynamics of the machine tool structure with the dynamics of the cutting process. They defined the regeneration phenomenon and the mode coupling effect as the principle chatter mechanisms. Merritt [3] presented stability theory for orthogonal turning His approaches were later adopted by many researchers [4, 5] and leaded to developing of fundamentals of chatter prediction by using the so called stability lobes diagrams. Further for stability prediction of milling to chatter was added intermittent nature of this process [8, 9, 10, 11, 12, 13]
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