Skip to main content
SpringerLink
Log in

A model for predicting chatter stability considering contact characteristic between milling cutter and workpiece

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

It has been demonstrated that chatter has a negative effect on machined surface quality during milling process. The identification of chatter is crucial for reducing its influence on machining integrity, especially for the milling process of curved surface. Change of cutter position will cause chip thickness to vary in milling process. Therefore, different contact characteristic between milling cutter and workpiece will be brought out. Compared with the traditional predictive model, a model for predicting chatter stability considering this contact characteristic is proposed in this study. Stability lobe diagrams at different cutter positions are proposed to predict milling stability by employing full-discrete method. A series of experiments are carried out to calibrate and verify the stable lobe diagram. The predicting result is in good agreement with experimental investigation for the stability characterization of curved surface milling process. The model proposed in this study could be used to improve machined quality for curved surface.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Öktem H, Erzurumlu T, Çöl M (2006) A study of the Taguchi optimization method for surface roughness in finish milling of mold surfaces. Int J Adv Manuf Technol 28(7–8):694–700

    Article  Google Scholar 

  2. Urbanski J, Koshy P, Dewes R, Aspinwall D (2000) High speed machining of moulds and dies for net shape manufacture. Mater Des 21(4):395–402

    Article  Google Scholar 

  3. Albertelli P, Cau N, Bianchi G, Monno M (2012) The effects of dynamic interaction between machine tool subsystems on cutting process stability. Int J Adv Manuf Technol 58:923–932

    Article  Google Scholar 

  4. Insperger T, Mann BP, Stépán G, Bayly PV (2003) Stability of up-milling and down-milling, part 1: alternative analytical methods. Int J Mach Tools Manuf 43(1):25–34

    Article  Google Scholar 

  5. Xie Q (2016) Milling stability prediction using an improved complete discretization method. Int J Adv Manuf Technol 83(5):815–821

    Article  Google Scholar 

  6. Altintaş Y, Budak E (1995) Analytical prediction of stability lobes in milling. CIRP Ann Manuf Technol 44(1):357–362

    Article  Google Scholar 

  7. Seguy S, Campa FJ, Lopez de Lacalle LN, Arnaud L, Dessein G, Aramendi G (2008) Toolpath dependent stability lobes for the milling of thin-walled parts. Int J Mach Mach Mater 4(4):377–392

    Google Scholar 

  8. Taylor FW (1907) The art of cutting metals. Sci Am 63:25942–25944

    Article  Google Scholar 

  9. Koenigsberger F, Tlusty J (1967) Machine tool structures—vol. I: stability against chatter. Pergamon Press, Oxford

    Google Scholar 

  10. Altintaş Y, Budak E (1995) Analytical prediction of stability lobes in milling. Ann CIRP 44(1):357–362

    Article  Google Scholar 

  11. Budak E, Altintas Y (1998) Analytical prediction of chatter stability in milling-part I: general formulation. J Dyn Syst Meas Control 120(1):22–30

    Article  Google Scholar 

  12. Merdol SD, Altintas Y (2004) Multi frequency solution of chatter stability for low immersion milling. J Manuf Sci E-T ASME 126(3):459–466

    Article  Google Scholar 

  13. Engin S, Altintas Y (2001) Mechanics and dynamics of general milling cutters: part I: helical end mills. Int J Mach Tools Manuf 41(15):2195–2212

    Article  Google Scholar 

  14. Ko JH, Altintas Y (2007) Time domain model of plunge milling operation. Int J Mach Tools Manuf 47(9):1351–1361

    Article  Google Scholar 

  15. Ding Y, Zhu L, Zhang X, Ding H (2010) A full-discretization method for prediction of milling stability. Int J Mach Tools Manuf 50(5):502–509

    Article  Google Scholar 

  16. Feng J, Sun Z, Jiang Z, Yang L (2015) Identification of chatter in milling of Ti-6Al-4V titanium alloy thin-walled workpieces based on cutting force signals and surface topography. Int J Adv Manuf Technol 82(9):1909–1920

    Google Scholar 

  17. Weingaertner WL, Schroeter RB, Polli ML, Oliveira Gomes J (2006) Evaluation of high-speed end-milling dynamic stability through audio signal measurements. J Mater Process Technol 179(1):133–138

    Article  Google Scholar 

  18. Li ZQ, Liu Q (2008) Solution and analysis of chatter stability for end milling in the time-domain. Chin J Aeronaut 21(2):169–178

    Article  Google Scholar 

  19. Cao H, Li B, He Z (2012) Chatter stability of milling with speed-varying dynamics of spindles. Int J Mach Tools Manuf 52(1):50–58

    Article  Google Scholar 

  20. Ko JH (2015) Time domain prediction of milling stability according to cross edge radiuses and flank edge profiles. Int J Mach Tools Manuf 89:74–85

    Article  Google Scholar 

  21. Zaghbani I, Songmene V (2009) Estimation of machine-tool dynamic parameters during machining operation through operational modal analysis. Int J Mach Tools Manuf 49(12–13):947–957

    Article  Google Scholar 

  22. Jin X, Sun Y, Guo Q, Guo D (2016) 3D stability lobe considering the helix angle effect in thin-wall milling. Int J Adv Manuf Technol 82:2123–2136

    Article  Google Scholar 

  23. Faassen R, Van de Wouw N, Nijmeijer H, Oosterling J (2007) An improved tool path model including periodic delay for chatter prediction in milling. J Comput Nonlinear Dyn 2(2):167–179

  24. Tsai CL, Liao YS (2010) Cutting force prediction in ball-end milling with inclined feed by means of geometrical analysis. Int J Adv Manuf Technol 46(5–8):529–541

    Article  Google Scholar 

  25. Naserian RS, Sadeghi M, Haghighat H (2007) Static rigid force model for 3-axis ball-end milling of sculptured surfaces. Int J Mach Tools Manuf 47(5):785–792

    Article  Google Scholar 

  26. Gu Y, Chen B, Zhang H, Guan Z (2001) Precise time-integration method with dimensional expanding for structural dynamic equations. AIAA J 39(12):2394–2399

    Article  Google Scholar 

  27. Ding, Y. (2011). Milling dynamics—stability analysis methods and applications. Dissertation, Shanghai Jiao Tong University.

  28. Gao G, Wu BH, Zhang DH, Luo M (2013) Mechanistic identification of cutting force coefficients in bull-nose milling process. Chin J Aeronaut 26(3):823–830

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Harbin University of Science and Technology, Harbin, 150080, China

    Caixu Yue & Xianli Liu

  2. Georgia Institute of Technology, Atlanta, GA, 30332-0405, USA

    Steven Y. Liang

Authors
  1. Caixu Yue
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Xianli Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Steven Y. Liang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Caixu Yue.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Yue, C., Liu, X. & Liang, S.Y. A model for predicting chatter stability considering contact characteristic between milling cutter and workpiece. Int J Adv Manuf Technol 88, 2345–2354 (2017). https://doi.org/10.1007/s00170-016-8953-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-016-8953-1

Keywords

Search

Navigation