Prediction of Chatter Stability in Bull-Nose End Milling of Thin-Walled Cylindrical Parts Using Layered Cutting Force Coefficients

During the bull-nose end milling operations of thin-walled structures, chatter usually occurs and adversely affects cutter performance, finished surface quality, production efficiency. To accurately predict stability, a suitable dynamic model with effective system parameters is required. In this article, three-degree-of-freedom (3-DOF) developed to analyze stability cylinders, in which dynamics mill along x-axis y-axis directions workpiece z-axis direction are taken into account. Then, cutter-workpiece engagement (CWE) extracted by employing slice-intersection-based approach. And layered cutting force coefficients identified considering influences varying diameters on speed. Thereafter, semi-discretization method (SDM) adopted compute lobe diagram (SLD). end, group tests carried out cylinder validate accuracy reliability proposed model, results show that predictions agree well experimental data.