.png){kind=icon}
.png){kind=icon}
Return
Chatter stability prediction and experimental validation of crest-cut end mills based on the full-discretization method
.png){kind=icon}
PRE
AI
F
K
X
G
L
Y
Y
P
X
DOI：10.1007/s00170-026-18671-9.png)
.png){kind=icon}
Original request for help.png){kind=icon}
Share.png){kind=icon}
Save
Abstract
En 中文
To address poor machining quality and high experimental risks caused by regenerative chatter in milling hard-to-cut materials, this paper proposes a chatter stability analysis and measurement validation framework for crest-cut end mills, combining a differential geometric model with the full-discretization method (FDM). First, the crest-cut end mill is axially discretized into cutting elements, and a static milling force model is established by analytically reconstructing the cutting point geometry. Based on this, a two-degree-of-freedom dynamic equation considering time-delay effects is constructed, and the FDM is used to formulate the state transition matrix for rapid stability calculation. A measurement system comprising impact hammer testing, cutting force acquisition, and chatter stability testing was built. Side milling experiments show that the prediction error for three-directional average cutting forces is less than 5%, accurately reproducing the non-harmonic distortion of force signals induced by the crest-cut geometry. Stability lobe diagrams (SLDs) validation confirms that, compared with the semi-discretization method (SDM), this method improves prediction accuracy by 46% in the low-speed region and reduces computation time by 24.07% in the high-speed region while maintaining equivalent accuracy. A systematic study reveals the nonlinear modulation rules of crest-cut parameters on stability, quantifies an amplitude saturation threshold of approximately 0.3 mm, and confirms that the inter-tooth phase shift is the decisive parameter for disrupting the regenerative feedback loop. This study provides a theoretical basis for the geometric parameter design of crest-cut end mills, and its excellent high-speed predictive performance can effectively reduce time-consuming and high-risk milling experiments.
Keywords:
Crest-cut end mill
Milling force
Dynamic modeling
Full-discretization method
Chatter stability
Journal
T
IF:
0
Papers:
2.0K
Citations:
0
Organization
Cited Papers