Time Domain Prediction of Side and Plunge Milling Stability Considering Edge Radius Effect

This article introduces a time domain model of side and plunge milling stability by considering cutting edge radius as well as dynamic motion of cutter center. Dynamic uncut chip thickness generated by side, plunge and ultrasonic milling can be simulated by tracking the cutter center positions at the present and previous vibrations with phase difference. Finally, the dynamic uncut chip thickness models as well as the mechanistic cutting force coefficients considering cutting edge radius are integrated into the time domain model. Especially, cross edge radius varies due to tool wear which affects cutting force coefficients and dynamics as well. Finally, the machining stability and vibrations are estimated using an identified transfer function and predicted cutting forces through the time domain solution. Experimental tests are compared against predicted results for validation of the proposed model.