FEA APPLICATIONS IN MILLING CHATTER STABILITY ANALYSIS

Regenerative chatter is a major hurdle to the productivity and quality of machining operations. This is because of the undesirable surface finish, excessive tool wear and deteriorated dimensional accuracy. Machining chatter analysis techniques examine the stability of a closed-loop model of machining forces and tool-workpiece system. This model is based on mathematical manipulations of machining forces and the dynamic responses of machining tooling. Almost all techniques derive the dynamic responses from physical test. In this paper, a novel approach of milling chatter stability analysis is introduced by using FEA applications to obtain the dynamic responses of the machine tool. The accuracy of this methodology is validated by machine shop tests.