| In the manufacturing industry, chatter is one of the primary factors limiting productivity and throughput. Chatter is recognized by its characteristic noise, the chatter marks, and/or the dissected chips.; The objective of this research is to develop a potentially more accurate operating range for chatter-free milling by taking a different look at stability chart profiles.; A single degree of freedom model is utilized to represent the end milling cutting process including the possibility of regenerative chatter. The resulting equation of motion is a parametrically excited system where the coefficients of the differential equation are time-varying. The perturbation method along with the method of multiple scales are extended in order to establish a stability criterion for the end milling process. The analytically developed stability criterion is then compared with experimentally obtained data for up-milling operations at half-immersion.; The research findings can be summarized by stating that the allowable axial depth of cut gradually decreases as spindle speed increases, within the machine/tool physical and mechanical limitations. This is contrary to most stability lobe diagrams published to date. |
