Global stability predictions for flexible workpiece milling using time domain simulation

This paper describes the use of peak-to-peak (PTP) force diagrams for machining stability prediction and validates its suitability for milling processes where the workpiece is considerably more flexible than the machine-tool system. These diagrams result from numerous executions of a time domain simulation which includes both the tool and workpiece dynamics and a mechanistic force model. The applicability of the PTP force diagram is validated experimentally through peripheral milling tests of thin-walled structures. Measured and simulated cutting forces are compared. It is shown that the PTP diagrams offer the global stability information which is provided by the traditional lobe diagram, while preserving the detailed, local information provided by time domain simulation.