A Mechanics Based Model for Study of Dynamics of Milling Operations

A unified mechanics based model with multiple degrees of freedom is developed and numerically simulated to study workpiece-tool interactions during milling of ductile workpieces with helical tools. A refined orthogonal cutting model is used at each section of the tool, and the milling forces are determined by using a spatial integration scheme along the axis of the tool. Both regenerative and loss of contact effects are considered in determining the cutting forces, which makes the model well suited for a wide range of milling operations. The model also allows for partial engagement of a tool with a workpiece, which is an important feature needed for milling operations with helical tools. Time domain simulations are carried out by using the developed model to predict the stability boundaries in the space of the tool spindle speed and the axial depth of cut. Poincaré sections are used to determine loss of stability from period-one motions to other motions such as two-period quasiperiodic motions, as a control parameter is varied.