Milling stability prediction and adaptive chatter suppression considering helix angle and bending

  • Chenxi Wang
  • Xingwu Zhang
  • Hongrui Cao
  • Xuefeng Chen
  • Jiawei Xiang


In milling process, chatter is one of the most unfavorable factors, which will reduce surface quality, limit tool life, accelerate tool wear, and decrease machining efficiency. To solve this problem, a great deal of research has been done in milling dynamic modeling and chatter suppression. In this paper, a new milling force calculation method considering helix angle and bending is presented, in which the instantaneous cutting area is calculated in an improved way. The milling dynamic equations are established based on the proposed model, and the stability limit is obtained with semi discretization method (SDM). Results show that tool bending and helix play important roles in stability lobe diagram (SLD). Subsequently, the stability prediction is verified in the milling experiment. Stability analysis can just provide the guidance for selection of milling parameters. In order to get higher efficiency and larger stable region, the time-domain least mean square (LMS) adaptive algorithm is constructed and implemented for chatter suppression in this article. For the sake of applying the method to experiments, the smart toolholder equipped with piezoelectric stack actuators is designed and mounted to a three-axis milling machine. The experimental results show that this method can suppress chatter effectively.


Helical end mills Tool bending Dynamic modeling Chatter suppression LMS algorithm 


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Funding information

This work is supported by the National Natural Science Foundation of China (Nos. 51405370 and 51421004), the Project Funded by Key Laboratory of Product Quality Assurance & Diagnosis (No. 2014SZS14-P05), and the open foundation of Zhejiang Provincial Key Laboratory of Laser Processing Robot/Key Laboratory of Laser Precision Processing & Detection (lzsy-12).


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Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2017

Authors and Affiliations

  • Chenxi Wang
    • 1
  • Xingwu Zhang
    • 1
  • Hongrui Cao
    • 1
  • Xuefeng Chen
    • 1
  • Jiawei Xiang
    • 2
  1. 1.State Key Laboratory for Manufacturing System Engineering, School of Mechanical EngineeringXi’an Jiaotong UniversityXi’anPeople’s Republic of China
  2. 2.Zhejiang Provincial Key Laboratory of Laser Processing Robot/Key Laboratory of Laser Precision Processing & DetectionWenzhou UniversityWenzhouPeople’s Republic of China

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