Dynamics and stability of milling process

Numerical and experimental investigations conducted into the dynamics and s tability of a range of milling operations are presented in this article. A unified mechanics based model developed to study workpiece-tool system dyna mics is used for the numerical studies. This model, which allows for both r egenerative effects and loss of contact effects, can be used for studying p artial-immersion, high-immersion, and slotting operations. Loss of stabilit y of periodic motions associated with milling operations is assessed by usi ng Poincare sections, and the numerical predictions of stable and unstable motions are found to compare well with corresponding experimental data. Bif urcations experienced by the periodic motions with respect to parameters su ch as axial depth of cut are numerically examined and discussed. The sensit ivity of dynamics to tooth passing period, feed rate, and feed direction is also discussed. (C) 2001 Elsevier Science Ltd. All rights reserved.