Radial depth of cut stability lobe diagrams with process damping effects

• A method to produce analytical radial depth of cut stability lobe diagrams that include process damping is described.
• The radial, rather than axial, depth of cut stability description is motivated by the format for many computer-aided manufacturing programs, which remove material layer-by-layer with a fixed axial depth and varying radial depth.
• Process damping is included because it enables higher material removal rates for hard-to-machine materials, which may have restricted cutting speeds ranges and cannot access the higher depths of cut available at high spindle speeds.
• Experimental stability results are presented for milling 1018 steel using coated carbide inserts.

This paper describes a method to produce analytical radial depth of cut stability lobe diagrams that include process damping. The stability limit was defined using the radial, rather than axial, depth due to the path planning approach for many computer-aided manufacturing (CAM) programs, which remove material layer-by-layer with a varying radial immersion. Experimental validation of the predicted stability limits was performed and the results are presented for both the process damping (low cutting speed) range and higher cutting speeds.