Time-domain simulation and testing for dynamic force and stability prediction in milling: Collaboration with feed rate scheduling software

Abstract

This paper describes: 1) the use of feed rate scheduling software to predict the radial depth of cut variation for three-axis milling toolpaths and; 2) the use of this radial depth profile in a time-domain simulation to predict dynamic cutting forces. The time-domain simulation, which also includes the tool tip frequency response functions and force model (which relates the cutting force components to the chip geometry) as inputs, enables dynamic force profiles to be predicted and parameter combinations that cause chatter to be identified. A ramp geometry is selected that provides constantly varying radial depth and force predictions are completed at multiple axial depths for comparison to measured forces.