Modeling chatter in peripheral milling using the Semi Discretization Method

In this paper the Semi Discretization Method, SDM, is employed to model chatter in peripheral milling using cutters with helical teeth. The process damping is included in the model using the equivalent viscous damper approach. The development is demonstrated first in straight cutting of plain surfaces. Stability lobes are established for these surfaces using an effective flank wear that also accounts for tool radial runout. A new approach of presenting the stability of the cut at different locations along the toolpath is developed; it is designated as the Stability Maps. The stability maps are established for 5-axis peripheral milling of three surfaces. Unlike the stability lobes, these maps are toolpath specific. The maps are verified using numerical simulations and cutting experiments.