Modelling of high-speed milling for prediction of regenerative chatter

High-speed milling is widely used to manufacture products. Examples of application areas arethe aerospace industry and mould industry. Cost-related considerations place high demands onthe material removal rate and surface generation rate. However, in this respect restrictions onthe process parameters, determining these two rates, are imposed by the occurrence of regenerativechatter. Chatter is an undesired instability phenomenon, which causes both reduced productsurface quality and tool wear. In this paper, the milling process is modelled, based on dedicatedexperiments on both the material behaviour of the workpiece material and the machine dynamics.Moreover, an effcient method for determining the chatter boundaries in the model is proposedand applied to the model in order to predict chatter boundaries in the process parameters, suchas the spindle speed and depth of cut, which both influence the material removal rate and surfacegeneration rate. Finally, experiments are performed to estimate these chatter boundaries in practice.Comparison of the modelled chatter boundaries with these experimental results confirm thevalidity of the model and the effectiveness of the stability analysis proposed