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Stability Analysis of 2-DOF End-Milling for a Range of Radial Immersions

Published

Author(s)

P V. Bayly, Tony L. Schmitz, D A. Peters, B P. Mann

Abstract

Low radial immersion end-milling involves intermittent cutting. If the tool is flexible, its motion in both the x- and y-directions affects the chip load and cutting forces, leading to chatter instability under certain conditions. Interrupted cutting complicates stability analysis by imposing sharp periodic variations in the dynamic model. Stability predictions for the 2-DOF model differ significantly from prior 1-DOF models of interrupted cutting. Stability boundaries of the milling process are determined by three techniques and compard in this paper: (1) a frequency-domain technique developed by Altintas and Budak; (2) a method based on time finite element analysis; and (3) the statistical variance of periodic 1/tooth samples in a time-marching simulation. Each method has advantages in different situations. The frequency-domain technique is fastest, and is accurate except at very low radial immersions. The temporal FEA method is significantly more efficient than time-marching simulation, and provides accurate stability predictions at small radial immersions. The veriance estimate is a robust and versatile measure of stability that can be applied to experimental tests as well as simulation.
Proceedings Title
Proceedings of the International Mechanical Engineering Conference and Exposition (IMECE 2002)
Volume
IMECE2002-34116
Conference Dates
November 17-22, 2002
Conference Location
New Orleans, LA, USA
Conference Title
International Mechanical Engineering Conference and Exposition

Keywords

Chatter, lobes, stability, time finite element analysis, variance

Citation

Bayly, P. , Schmitz, T. , Peters, D. and Mann, B. (2002), Stability Analysis of 2-DOF End-Milling for a Range of Radial Immersions, Proceedings of the International Mechanical Engineering Conference and Exposition (IMECE 2002), New Orleans, LA, USA (Accessed July 21, 2024)

Issues

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Created December 31, 2001, Updated October 12, 2021