An Improved Time Domain Simulation for Dynamic Milling at Small Radial Immersions

This paper presents an improved milling time domain model to simulate vibratory cutting conditions at very small radial widths of cut. The improved kinematics model allows simulation of very small radial immersions. The model can predict forces, surface finish, and chatter stability, accurately accounting for non-linear effects that are difficult to model analytically. The discretized cutter and workpiece kinematics and dynamic models are used to represent the exact trochoidal motion of the cutter, and to investigate the effects of forced vibrations and changing radial immersion due to deflection and vibrations on chatter stability. Three dimensional surface finish profiles are predicted and are compared to measured results. Stability lobes generated from the time domain simulation are also shown for various cases.