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Abstract

The small fillet aluminum alloy cavity is a typical structure. The analysis and experiment have been conducted on the chatter at the corner of the aluminum alloy during milling process, the results show that continuity changing of spindle speed acceleration and size effect (special ploughing effect) are the main factors of chatter. The Axial Depth of Cut–Spindle Speed Analysis Method is not effective to reflect the chatter, the previous experiments have proved this point. This study investigated the cutting chatter at the corner during the circular milling process by using a new polar coordinates geometric model. The mechanics of the process are modeled by considering size effect, while regarding the ploughing effect as a new important factor. The chatter of circular milling is verified and tested both at the reduced speed of spindle and reduced feed per teeth. Acceleration of spindle speed can cause chatter and ploughing effect for enhanced chatter stability because the changed process damping occured at small size.

Keywords

AL7075 spindle speed ploughing effect chatter

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Application of a new geometric modeling on machining cutting chatter analysis

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