Determination of Chatter-Free Cutting Mode in End Milling

Author(s): Petrakov Y. V.1, Ohrimenko O. A.1, Sapon S. P.2, Sikailo M. O.1, Fedorynenko D. Y.3

Affiliation(s):
1 National Technical University of Ukraine “Igor Sikorsky Kyiv Polytechnic Institute”, 37, Beresteiskyi Ave, 03056, Kyiv, Ukraine;
2 Chernihiv Polytechnic National University, 95, Shevchenka St., 14035, Chernihiv, Ukraine;
3 Tohoku University, 2, Chome-1-1 Katahira, Aoba Ward, Sendai, 980-8577, Miyagi, Japan

*Corresponding Author’s Address: [email protected]

Issue: Volume 11, Issue 2 (2024)

Dates:
Submitted: February 29, 2024
Received in revised form: May 25, 2024
Accepted for publication: June 17, 2024
Available online: July 5, 2024

Citation:
Petrakov Y. V., Ohrimenko O. A., Sapon S. P., Sikailo M. O., Fedorynenko D. Y. (2024). Determination of chatter-free cutting mode in end milling. Journal of Engineering Sciences (Ukraine), Vol. 11(2), pp. A1–A11. https://doi.org/10.21272/jes.2024.11(2).a1

DOI: 10.21272/jes.2024.11(2).a1

Research Area: Machines and Tools

Abstract. Chatter accompanies the cutting process and is the main obstacle to achieving precision and productivity in milling operations. To reduce the amplitude of vibrations, it was proposed to use a stability lobes diagram (SLD) when assigning cutting modes. The machining system in end milling was represented by a two-mass dynamic model in which each mass has two degrees of freedom. The behavior of such a system was described by a structure with two inputs, in-depth and cutting feed, and a delay in positive feedback on these inputs. A new criterion was applied to design the SLD based on an analysis of the location of the machining system Nyquist diagram on the complex plane. The algorithm for designing a stability chart was developed into an application program, a tool for the technologist-programmer when assigning cutting modes. A method for parameter identification necessary for designing the dynamic system “tool – workpiece” was proposed. The effectiveness of the developed method was proven experimentally when the choice of spindle speed during end milling allows one to reduce the roughness parameter Ra from 3.2 µm to 0.64 µm at the same feed rate of 650 mm/min.

Keywords: end milling, simulation, process innovation, stability lobes diagram.

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