On the effect of process stiffening and process damping on milling dynamics

The dynamic contact between the flank face of the tool and the workpiece surface can affect process stability and prevent chatter. Such an interaction is typically interpreted as process damping and, thus, as dissipative, but can also have a distinct stiffening effect. In this work, the impact of both process stiffening and process damping on the dynamics and stability of milling processes is investigated, considering different spindle speeds and engagement conditions. Specifically modified tools were used for this purpose, including those with conventional and structured flank face chamfers, which led to significantly different characteristics of the flank face interactions.