Study on the construction mechanism of stability lobes in milling process with multiple modes

Abstract

The stability of milling process dominated by multiple modes was traditionally predicted in the time domain by only selecting the most flexible mode. This paper theoretically studies the construction mechanism of stability lobes by simultaneously considering all dominant modes and provides an efficient method to predict stability lobes of milling systems with multiple modes in the time domain. It is theoretically proved that the effective stability lobes of milling system with multiple modes is made up of the lowest envelop of the stability lobes achieved with each single mode; hence, lowest envelop method (LEM) is established to predict the ultimate stability lobe by taking the lowest envelop of a group of stability lobes, which are calculated by separately considering different dominant modes composing the overall dynamic compliance. Typical advantage of LEM lies in that the computation time and the memory usage required in stability prediction can be greatly reduced for time domain solution. Moreover, the accuracy of prediction can be increased, when the effects of multiple modes are taken into account instead of considering only the most flexible mode. Formulation of the dynamic milling process with multiple modes is derived in semi-discrete time domain by including the effects of multiple delays. A series of simulations and experiments demonstrate the high efficiency and validity of LEM.

Determination of optimal geometrical parameters of peripheral mills to achieve good process stability

“…In this section, SLDs are drawn using an updated zeroorder semi-discretization method [20,21], which is briefly described as follows.…”

Low-frequency chatter genesis during inclined surface copy-milling with ball-end mill: Experimental study

“…It is also noticed that feed per tooth has great effect on the stability lobes when cutter runout occurs in the case of flat-end mill machining. Multiple modes influence on the stability lobes is examined by Wan et al (2015) using the semi-discretization method. The lowest envelop method (LEM) is used for the ultimate stability lobe prediction.…”

Influence of frictional mechanism on chatter vibrations in the cutting process–analytical approach

“…thread milling [22] are used. Moreover, the problem of stability lobes in milling process with multiple modes is analysed [23]. In this paper, the useful method of the lowest envelop stability lobes is developed.…”