Investigation of machining stability in micro milling considering the parameter uncertainty

Abstract

Micro milling can fabricate miniaturized components using micro end mill at high rotational speeds. A major obstacle that limits the productivity in machining operations is the presence of machine tool chatter. The analysis of machining stability in micro milling plays an important role in characterizing the cutting process, in estimating the tool life and optimizing the process. But the majority of the traditional models used to predict chatter stability assume that parameters remain unchanged. In reality, the parameters affecting the machining stability vary with the high spindle speed and dynamic characteristic of the milling system. A numerical analysis and experimental method is present to investigate the machining stability in micro end milling process considering the parameter uncertainty. A robust chatter stability model based on the analytical chatter stability milling model is developed, and the edge theorem and the zero exclusion condition are used. The method is verified experimentally for micro milling operations while considering a changing cutting coefficient and natural frequency.

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