Stability Analysis in Face Milling Operations, Part 1: Theory of Stability Lobe Prediction

Abstract

This paper involves development of an algorithm to predict stability lobes in face milling operation. The modeling is based on frequency domain analysis and is an extension of Budak and Altintas to a three dimensional case. It considers the effects of insert and cutter geometry, cutting conditions, process nonlinearity, entry and exit angles and the fully dimensional structural dynamics of both the machine tool and workpiece, including axial dynamics which are often neglected by many researchers. In addition, the predictive capability of stability lobes by the presented models is compared with those results obtained by time domain simulations.