Time-Domain Simulation on Plunge Milling Ti-6Al-4V

The research of cutting force and vibration has been gaining significant attention to improve machining efficiency and tool life in processing metals. In this paper, the plunge milling system is reduced to 3-DOF vibration system, and dynamical theoretical model and instantaneous undeformed chip thickness models are established based on dividing cutter tooth into finite number of small differential elements in the radial direction and discrete time domain. Based on regenerative chatter theory, the cutting force and vibration can be simulated by numerical algorithm. Compared the simulation results with experiments data, the milling force and vibration have a good agreement, which testify the correction of those models