Chatter Stability Improvement of a Slender Milling Tool via a Dynamics Variation Mechanism

Abstract

In this study, a milling tool with variable mass and stiffness is developed for chatter reduction. The proposed milling tool is hollow with a solid core threaded inside it. As the core is screwed in or out of the tool body, the equal mass and stiffness of the tool are changed. Therefore, the tool's frequency response function (FRF) is changed to affect the stability lobe diagram (SLD) position. Moving the SLDs can stabilize an unstable cutting process. With respect to the FRFs obtained from modal test, the idea is proven using an experimental and analytical approach. The optimum core position for every spindle speed is also presented. The developed tool stability is then investigated in a realistic cutting condition. The cutting process sound analysis and surface finish visual inspection results reveal the performance of the proposed system in chatter reduction of a slender milling tool.