Modeling and measurement of micro end mill dynamics using inverse stability approach

Micro-milling applications require high precision and dimensional accuracy. Chatter vibrations arising from unstable cutting conditions cause poor surface finish and damage to the cutting tools. Tool point frequency response functions (FRF); needed to generate stability diagrams, cannot be determined experimentally due to very small tool size. In this study an analytical model for tool point FRF of micro end mills is presented. An inverse algorithm is proposed to correct geometric representation and damping of the tool. The model and the correction methodology presented improve productivity and part quality in micro-milling through accurate prediction of chatter stability limits, enabling better cutting parameter selection