Modeling, analysis and stability of milling processes including workpiece effects
O. Rott (Weierstrass Institute, Germany) and D. Hömberg (TU Berlin and WIAS)
The modeling of milling dynamics and the determination of stable cutting conditions become increasingly important for the control of manufacturing processes. Analytic approaches and time domain simulations based on simplified dynamic systems are currently used to identify chatter-free, i.e. stable, machining conditions. We have extended a common dynamic system, i.e. a harmonic oscillator, by a continuous, linear elastic model describing the dynamic behavior of the workpiece. We use a widely studied, empirical cutting force model to describe the coupling of both systems.
Here we report the gradual derivation of the governing equations. Then we show the existence and uniqueness of a solution for the coupled system. Finally we present time domain numerical simulations permitting a first estimate of the stability of the extended dynamic milling system.