Note on a novel method for machining parameters optimization in a chatter-free milling process

Abstract Machining parameters optimization in a chatter-free milling process is a common issue for practical engineers at shop floor. The detailed and easily applicable optimization algorithm taking the milling mechanism into account is absent to date. This communication deals with the procedures of optimization of machining parameters in the chatter-free milling process. First, the model of machining parameters optimization is given based on the milling dynamics. The optimization objects are to minimize the tool vibration response and maximize the material removal rate, and the constraint conditions are to keep the milling process chatter-free or stable and let the spindle speed below a predefined one. Emphasis is put on how to select the spindle speed for reducing the tool vibration response and maximization of the material removal rate simultaneously. Augmented Lagrangian function method is employed to solve the nonlinear optimization problem. A numerical example is provided to show the effectiveness of the developed results. Besides, improvements on the calculation scheme of the tool vibration response have been made.