Relative Assessment of the Dynamic Behavior and Cutting Performance of a Bonded and a Cast-Iron Horizontal Milling Machine

Abstract

The dynamic behavior and the cutting performance of a horizontal milling machine, the structure of which was fabricated by bonding, are compared with those of a machine of nominally identical specification but containing cast structural components. Theoretical work predicted the chatter performance of these two machines from vibration tests, using dynamic cutting coefficients characterizing material behavior. The relative performance of the two machines is discussed with the aid of the predicted stability charts, relating to specific cutting conditions, and in a more general form, through merit charts. The stability charts were obtained also by cutting tests, carried out with a helix and a slot cutter. Correspondence between the predicted and measured stability charts was satisfactory. The chatter performance, measured in terms of the maximum stable width of cut, of the bonded machine was substantially better than that of the cast machine for both types of cutters.