Stability Analysis Of High Speed Milling And The Prediction Of The Tool Point FRF

As an advanced metal cutting way, High speed milling has a wide range of applications in the aviation、aerospace、automotive and mould manufacturing. It has lesser cutting force and thermal deformation, high processing quality and material removal rate, and processing lower-cost advantages. Although there are many advantages of high speed milling, but the existence of the chatter will directly influence the stability of the cutting process, bring machining deformation, reduce the processing surface quality、the production efficiency、the life of the tools and machine and even become a direct threat to the safety of the operator, often lead to a large number of high speed machine can not make full use of their high performance. Therefore, the stability analysis and the prediction of the milling process to avoid the milling process instability have significant research significance.In this paper, the stability lobe diagrams method is used to study the chatter and stability prediction of the high speed milling. After establishing the milling system’s dynamic model, the paper puts forward a easy way to get the stability which called the cutting edges of the average angle position method. And it is compared with the traditional Fourier series comparison method and time domain simulation method, which is more accurate but slightly complex, verify the accuracy of this method.Based on this method, the analysis of the stability lobe diagrams can be used to obtain the optimization milling spindle speed for certain system, which greatly improve the milling process of material removal efficiency (MMR), so we can select some reasonable parameters of milling system and spindle speed to optimize the milling system. Structure parameters and process parameters of the milling process are compared on the effect of the milling stability, to get different stability lobe diagrams which change with the parameters of the milling. It is very meaningful to improve the quality of products.Then, the paper use the method of Receptance Coupling Substracture Analysis (RCSA) to get the tool point frequency response function (FRF), use E-B beam theory model to summarize the coupling formula of various situations. Utilizing Matlab simulation, the tool-tool holder system of the simplified model coupling method is validated, and putting forward a technique of adjusting the length of the cutting tools to enhance stability for milling by the analysis results.Second, the simplified model of the milling cutter simplified method is discussed, it will be simplified to two section beam model, the calculation will be convenient, the final prediction’s accuracy will be improved. Then it puts forward some other measures to improve the efficiency and accuracy of the prediction.Finally, the conclusions are drawn and the further research directions of the stability analysis in high speed milling are pointed out. And it puts forward some problems need to be solved in the further research process.