Multiple chatter frequencies in milling processes

Analytical and experimental identifications of the chatter frequencies in milling processes are presented. In the case of milling, there are several frequency sets arising from the vibration signals, as opposed to the single well-defined chatter frequency of the unstable turning process. Frequency diagrams are constructed analytically and attached to the stability charts of mechanical models of high-speed milling. The corresponding quasiperiodic solutions of the governing time-periodic delay-differential equations are also identified with some milling experiments in the case of highly intermittent cutting.