Abstract
ABSTRACTThe development of advanced performance materials by foundrymen allows new designs of components with similar mechanical resistance but lower thicknesses. This accentuates the well-known problems in machining cutting systems (static form errors, forced vibrations, and chatter), which appear increasingly early. These problems are particularly severe in the case of rotating parts in the field of aeronautics. Currently, the machining time for impellers and blisks can be improved so that new cutting tools with innovative features are continually developed. Barrel type or curved end mills will have a significant impact on the manufacturing of aircraft components during incoming years. In this paper, a time domain method is proposed for the first time to predict stability in milling operations when using these tools. The dynamic cutting forces are first obtained and then used to plot stability contour maps. Key aspects, such as tool orientation angles, several dynamic modes, and runout were also considered. Finally, chatter tests were performed for a low-stiffness mechanical system to validate the model. The presented maps indicate chatter severity and may be used for chatter prediction and productivity improvement.
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