Title: Modelling and verification of stability of micro-milling process

Authors: Adapa Sainath; G.L. Samuel

Addresses: Department of Mechanical Engineering, Indian Institute of Technology Madras, Chennai-600-036, India ' Department of Mechanical Engineering, Indian Institute of Technology Madras, Chennai-600-036, India

Abstract: In micro milling, the inherent instability of the cutting process limits the different combinations of parameters to achieve the required material removal rate and surface roughness. A stability lobe diagram shows the boundary between chatter-free machining operations and unstable processes, in terms of axial depth of cut as a function of spindle speed. These diagrams are used to select chatter-free combinations of machining parameters. Time domain simulation models of milling can be used to predict chatter and construct such stability charts. Hence, a chatter prediction model incorporating feed rate influence along with spindle speed and depth of cut, will be helpful. In the present work, time domain simulations of micro-milling were performed and chatter was predicted for three different feed rate conditions. Subsequently, this was validated with experiments by machining series of slots using 1 mm solid carbide end-mill on brass workpiece. There is good agreement between experimental and simulated results.

Keywords: micromilling; time domain simulation; machinability; modelling; stability verification; micromachining; end milling; brass machining; material removal rate; MRR; surface roughness; stability lobe diagrams; axial depth of cut; spindle speed; stability charts; chatter prediction models; feed rate.

DOI: 10.1504/IJMMM.2014.067312

International Journal of Machining and Machinability of Materials, 2014 Vol.16 No.3/4, pp.229 - 258

Received: 10 Oct 2013
Accepted: 19 Jul 2014
Published online: 14 Feb 2015 *

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