Time domain prediction of milling stability according to cross edge radiuses and flank edge profiles

• End milling stability is predicted considering cross edge radiuses and flank edge profiles.
• The process damping effect is simulated according to the interactions between the edge profiles and undulation on the machined surface.
• The fast and accurate model is proposed to simulate the process damping forces and the stability.
• The simulation matches with the experimental phenomenon that tool wear causes high process damping.

This article proposes a time domain model for predicting an end milling stability considering process damping caused by a variety of cross edge radiuses and flank profiles. The time domain model of calculating indentation areas, as well as regenerative dynamic uncut chips, is formulated for the prediction of the stabilizing effect induced by interference areas between the edge profiles and undulation left on a workpiece. The interference area generates forces against the vibration motion, which acts as a damping effect. In the model, the present and previous angular position of cross radiuses and flank edge profiles are located to calculate the dynamic uncut chip as well as indentation area based on a time history of the dynamic cutter center position. The phenomenon that chatter is damped according to cross edge radiuses and flank edge profiles is successfully simulated with the proposed dynamic model and validated through the extensive experimental tests.