Computerized Simulation And Experimental Study On The Stability Of Milling Processes

Machining chatter is an intensive and relative vibration between the cutting tool and the workpiece in cutting processes, which belongs to self-excited vibration. It is a significant work to analyze and control chatter because its occurrence inevitably brings about the pollution of environment noises, decrease the surface quality, the cutting efficiency and the tool life, even results in the casualties. Firstly, the mechanism of chatter is analyzed and studied. Based on the establishment of the dynamics model of milling processes with two degrees of freedom, the end-milling processes are simulated in time domain by using numeric simulation technology. The results of the simulation show that it is practicable of the established model to depict the milling progress.Secondly, the milling stability is analyzed based on experiment method. The influence factors of the forced vibration and chatter are studied in milling by observing and analyzing the machined surface and the spindle vibration. Chatter can be weakened when increasing the feed rate, or decreasing the cutting depth and cutting width. And, the fashions of milling also affect the chatter greatly. Chatter is easier to occur in climb mode than conventional mode. At the same time, the amplitude of the forced vibration will increase when speed, feed rate, cutting depth or cutting width increasing. The results of the experiment analysis are in accord with the simulation and give the methods of milling vibration control. Lastly, on-line cutting vibration monitoring system based on virtual instruments technology is established. The system is with flexibility, real-time and expansibility. The experimental system has been successfully applied in practice...