Stability prediction of milling process with variable pitch and variable helix cutters

Abstract

The use of variable pitch or helix cutters is a known means to prevent chatter vibration during milling. In this article, an alternative method based on an improved semi-discretization method is proposed to predict the stability of variable pitch or variable helix milling. In order to consider the effect of distributed system delays attributed to helix variation, the average delays were calculated for each flute after the engaged cutting flutes were divided into a finite number of axial elements. Meanwhile, a straightforward integral force model, which can consider the piecewise continuous regions of the cutting that describe the helix angle is used to determine the cutting force. Through comparisons with prior works, time-domain simulations, and cutting tests, the proposed approach was verified. In addition, the method was applied to examine the effect of tool geometries on stability trends. Several phenomena for certain combinations of pitch and helix angles are shown and explained.