Analytical Modeling, Design and Performance Evaluation of Chatter-Free Milling Cutter With Alternating Pitch Variations

Study of the effective cutter radius for end milling of free-form surfaces using a torus milling cutter

Modeling and Analysis for Five-Axis High Speed Milling Process Based on Cutter Optimal Kinematics Performance

The overall goal of the research is the integration of geometric and mechanistic models for cutting process simulation and feedrate optimization. Five-axis milling methods are used in industries such as aerospace, automotive and mold for free-form surface machining. In these process, surface quality and material removal rate are of very important. Conservative cutting parameters have been mostl...

Computing Cutter Engagement Values in Milling Tessellated Free-Form Surfaces

High speed milling (HSM) has great potential use in die/mold cutting, but traditional machining plans do exploit HSM capabilities effectively. An important consideration for in HSM is to limit cutting force variations, and one way to do so is to reduce Cutter-Workpiece engagement (CWE) variations. CWE is measured as the area of the tool instantaneously engaged with the part. Estimating CWE as a...

An Analytical Design Method for Milling Cutters With Nonconstant Pitch to Increase Stability, Part 2: Application

Chatter stability in milling can be improved significantly using variable pitch cutters. The pitch angles can be optimized for certain chatter frequency and spindle speed ranges using the analytical method presented in the first part of this two-part paper. In this part, the improvement of productivity and surface finish are demonstrated in three example applications. It is shown that chatter s...

An Analytical Design Method for Milling Cutters With Nonconstant Pitch to Increase Stability, Part I: Theory

Chatter vibrations result in reduced productivity, poor surface finish and decreased cutting tool life. Milling cutters with nonconstant pitch angles can be very effective in improving stability against chatter. In this paper, an analytical stability model and a design method are presented for nonconstant pitch cutters. An explicit relation is obtained between the stability limit and the pitch ...