Prediction of chatter considering the effect of axial cutting depth on cutting force coefficients in end milling

Abstract

The cutting stability of machine tools during operation is dependent on many parameters including the spindle speed and axial cutting depth. Cutting force coefficients may change due to the effect of heat and influence the stability lobe diagram during dry cutting aluminum alloy. Based on the identification of cutting force coefficients, the dependence of cutting force coefficients on the spindle speed and axial cutting depth are investigated. The spindle speed had a slight effect on cutting force coefficients, while the axial cutting depth greatly affected the cutting force coefficients. The cutting force coefficients were expressed as functions of axial cutting depth, and based on varying cutting force coefficients with axial cutting depths, the stability lobe diagram is modified. Then, stability lobe diagrams of varying cutting force coefficients are compared to that of constant cutting force coefficients, and the stability lobe diagram with varying cutting force coefficients was verified through a series of experiments.