Chatter milling modeling of active magnetic bearing spindle in high-speed domain

A new dynamical modeling of Active Magnetic Bearing Spindle (AMBS) to identify machining stability of High Speed Milling (HSM) is presented. This original modeling includes all the minimum required parameters for stability analysis of AMBS machining. The stability diagram generated with this new model is compared to classical stability lobes theory. Thus, behavior's specificities are highlighted, especially the major importance of forced vibrations for AMBS. Then a sensitivity study shows impacts of several parameters of the controller. For example, gain adjustment shows improvements on stability. Side milling ramp test is used to quickly evaluate the stability. Finally, the simulation results are then validated by HSM cutting tests on a 5 axis machining center with AMBS.

► Explicit dynamical modeling of Active Magnetic Bearing Spindle (AMBS) for milling. ► Sensitivity analysis of some critical parameters. ► Experimental High-Speed Machining (HSM) ramp test. ► Comparison of asymptotic stability and forced vibrations. ► Demonstration that forced vibrations limit the use of this spindle for HSM.