Modelling and simulation of chatter in milling using a predictive force model

A predictive time domain chatter model is presented for the simulation and analysis of chatter in milling processes. The model is developed using a pr edictive milling force model, which represents the action of milling cutter by the simultaneous operations of a number of single-point cutting tools a nd predicts the milling forces from the fundamental workpiece material prop erties, tool geometry and cutting conditions. 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 acco unt. Runge-Kutta method is employed to solve the differential equations gov erning the dynamics of the milling system for accurate solutions. A Windows -based simulation system for chatter in milling is developed using the pred ictive model, which predicts chatter vibrations represented by the tool-wor k displacements and cutting force variations against cutter revolution in b oth numerical and graphic formats, from input of tool and workpiece materia l properties, cutter parameters, machine tool characteristics and cutting c onditions. The system is verified with experimental results and good agreem ent is shown. (C) 2000 Elsevier Science Ltd. All rights reserved.