Efficient Prediction of Stability Boundaries in Milling Considering the Variation of Tool Features and Workpiece Materials

Abstract

Theoretical stability analysis is a significant approach to predicting chatter-free machining parameters. Accurate milling stability predictions highly depend on the dynamic properties of the process system. Therefore, variations in tool and workpiece attributes will require repeated and time-consuming experiments or simulations to update the tool tip dynamics and cutting force coefficients. Considering this problem, this paper proposes a transfer learning framework to efficiently predict the milling stabilities for different tool–workpiece assemblies through reducing the experiments or simulations. First, a source tool is selected to obtain the tool tip frequency response functions (FRFs) under different overhang lengths through impact tests and milling experiments on different workpiece materials conducted to identify the related cutting force coefficients. Then, theoretical milling stability analyses are developed to obtain sufficient source data to pre-train a multi-layer perceptron (MLP) for predicting the limiting axial cutting depth (aplim). For a new tool, the number of overhang lengths and workpiece materials are reduced to design and perform fewer experiments. Then, insufficient stability limits are predicted and further utilized to fine-tune the pre-trained MLP. Finally, a new regression model to predict the aplim values is obtained for target tool–workpiece assemblies. A detailed case study is developed on different tool–workpiece assemblies, and the experimental results validate that the proposed approach requires fewer training samples for obtaining an acceptable prediction accuracy compared with other previously proposed methods.