Chatter Prediction in Endmilling Using Dynamic Cutting Force Modeling

Cutting process, in general, is a closed-loop system consisting of structural dynamics and cutting dynamics, with the cutting forces and the relative displacements between tool and workpiece being the associated variables. There have been a number of works on modeling the cutting process of endmilling, most of which assumed that either one of the tool or workpiece be negligible in tis displacement. In this paper, the relative displacement between tool and workpiece was considered. The proposed model used experimental modal analysis for structural dynamics and an instantaneous uncut chip thickness model for cutting dynamics. Simulation of the model, a time varying cutting system, was performed using 4th order Runge-Kutta method. Subsequent simulation results were utilized to predict chatter over a variety of experiments in slotting operation, showing good agreement.