Chatter stability analysis of variable speed milling with helix angled cutters

Abstract

The number of factors considered in the establishing of chatter model for regenerative chatter would directly affect the accuracy of numerical analysis. In this paper, considering the helix angle of cutter, the establishment method of three degrees of freedom complex model is investigated synthetically. An improved semi-discretization method is adopted for the prediction of milling stability of variable speed milling with helix angle. The influences of milling cutter helix angle, radial immersion rate and variable speed modulation coefficient on chatter suppression in milling process are studied. The results show that the selection of milling cutters with different helix angles has a certain influence on the overall chatter stability, especially the effect cannot be ignored under local special machining conditions. Excessive radial immersion rate will increase the probability of chatter. Compared with constant speed milling, the chatter can be suppressed obviously by variable speed milling, and the selection of variable speed modulation coefficient will directly affect the suppression effect of chatter.