Vibration analysis in high speed rough and finish milling hardened steel

High speed milling (HSM) as a cutting process in mould and die industries has been gaining in popularity over recent years due to the ability to machine difficult-to-cut workpiece materials with increased productivity due to an enhanced tool life. A literature survey, however, suggests that work on understanding the chatter vibration effects caused due to various cutter path orientation effects when HSM is scant. This paper presents an approach to derive the vibration analysis on the cutter path orientations employed in rough and finish milling via the use of fast Fourier transform (FFT) analysis on the cutting force signatures obtained based on two cutter condition factors, namely the use of new and worn cutters. The comparative results showed that employing high axial depths of cut (10 mm⩽Ad⩽20 mm) for both up and down milling entailed minimal vibrational effects. When finish milling, FFT analysis suggested that employing a vertical upward orientation resulted in minimal vibrations regardless of the cutter condition.