STUDY ON THE PREDICTION OF STABILITY CONDITIONS IN MILLING PROCESS USING A SOLID FLAT-END MILL CUTTER

Abstract

The study was conducted to predict the stable cutting status and build a model to predict the stable diagram in the milling process
of SKD11 steel using a solid flat-end mill cutter. The instantaneous dynamic cutting forces and stable cutting conditions were modeled
as functions of different parameters including cutting tool parameters, workpiece parameters, cutting force coefficients, dynamics
structural parameters of the technological system, cutting parameters, etc. The instantaneous dynamic cutting forces were modeled
and verified by experimental process with predicted results to be very close to the measured results, although there are still many
differences in the instantaneous values of the cutting forces. A prediction model of stability conditions was also built and verified
through the experimental process. With the technology system that was used in this study, the milling process will be stable when
machining at a depth of cut less than 0.25mm with all values of spindle speed. Additionally, the stable and unstable points in the
predicted stability diagram were verified with ensuring the accuracy. However, at the transition points between stable and unstable
zones, it seems that the accuracy of model is lower. The studies to verify and improve the model to predict the stable condition with
different cutter - workpiece material pairs using different technology systems are the next direction of this study.