Milling Stability Prediction under Multi-effect Synergy

During the milling process, chatter vibration is prone to occur when the spindle, tool, and workpiece interact with each other under certain parameters, which seriously affects machining efficiency and reduces machining quality. Therefore, it is necessary to study the mechanism and influencing factors of chatter vibration, predict the stability of the milling system through a multi-effect synergistic dynamic model, and obtain the machining parameters of stable milling through analysis. Based on the traditional milling model, this article considered the regeneration effect, process damping effect, and modal coupling effect, and also considered the friction effect of the front cutting surface for friction-induced chatter, to make the model’s prediction range more accurate. Then, a milling dynamic model was established combining multiple effects, and its stability lobe diagrams were solved by the full-discretization method. The accuracy of the model was verified through milling stability experiments. The experimental results are basically consistent with the predicted stability lobe diagrams, indicating that the milling stability prediction model considering multi-factor coupling of the milling model is correct. Finally, the influence of various effects on milling stability was analyzed, with a focus on the influence of friction effects.