A new chatter stability criterion in milling process simulation

Modelling of the dynamic processes in milling and the determination of chatter-free cutting conditions are becoming increasingly important in order to facilitate effective planning of the machining operations. In this study, a new chatter stability criterion is proposed, which can be used for the time domain milling process simulation and model-based milling process control. A predictive time domain model is presented for the simulation and analysis of the dynamic cutting process and chatter in milling. The instantaneous undeformed chip thickness is modelled to include the dynamic modulations caused by the tool vibrations so that the dynamic regeneration effect is taken into account. The cutting force is determined by using a predictive machining theory. A numerical method is employed to solve the differential equations governing the dynamics of the milling system. The work proposes that the ratio of the predicted maximum dynamic cutting force to the predicted maximum static cutting force is used as a criterion for the chatter stability. Comparisons between the simulation and experimental results are given to verify the new model.