Efficient Method for Prediction of Stability in Low Immersion Milling

This paper presents cutting force prediction algorithm for low immersion end-milling, using an efficient dynamic force modeler. The geometric simulation of milling process was performed, using the B-Rep solid modeling techniques. For predicting stability lobes, two methods were used for prediction of stability lobes: the frequency domain technique and the time finite element analysis (TFEA). The frequency domain technique is faster and except for low immersion milling, is accurate. The TFEA method forms an approximate solution by dividing the cutting time into a finite number of elements. This approximated solution is then matched with the exact one for free vibration to obtain a discrete linear map. The comprehensive time domain simulation is used, in order to verify stability lobes diagram obtained by frequency domain technique and TFEA method.