A Comprehensive Dynamic End Milling Simulation Model

Abstract

This paper presents a comprehensive time domain model that simulates end milling processes under general cutting conditions. Over an extensive range of axial depths of cut, the model can accurately predict regenerative forces and dynamic responses by considering varying dynamics along the cutting depth, three-dimensional forces, and cutting tool geometries. The prediction of stability limit is validated under cutting conditions of both large depths and very small radial immersions. In addition, three-dimensional surface profiles under both stable and chatter conditions are predicted and compared with measured ones. A new method to extract cutting pressure coefficients is also introduced and applied to the experimental validations.