Stability lobes in milling including process damping and utilizing Multi-Frequency and Semi-Discretization Methods

In this work the equivalent viscous model of process damping is integrated into the Multi-Frequency Solution and the Semi-Discretization Method to establish the stability lobes in milling. The basic formulations are presented along with the comparisons between the two approaches using examples from the literature. A non-shallow cut is employed in the comparisons. Assessing the performance of the two methods is conducted using time domain simulations. It is shown that the Semi-Discretization Method provides accurate results over the whole tested range of cutting speed, whereas higher harmonics are required to achieve the same accuracy when applying the Multi-Frequency Solution at low speeds. Stability lobes established using the Semi-Discretization Method are verified experimentally. It is shown that these lobes agree closely with cutting tests.

► Developing Multi-Frequency Solution and Semi-Discretization Methods including process damping. ► Comparing the two methods at low speed cuts and highly damped systems. ► Higher harmonics are needed at low speed cuts and highly damped systems. ► In highly damped systems with no process damping, stability is higher at low speeds.