Robust Chatter Mitigation Control for Low Radial Immersion Machining Processes

Abstract

Chatter is a typical kind of unstable dynamics often encountered in machining processes, which often results in overcut and rapid tool wear. Hence, chatter phenomenon worsens the surface quality and reduces productivity in milling systems as well. Recent years have witnessed a surging industrial demand of high quality and high efficiency machining. Specifically, for low radial immersion milling situation, large depth of cuts is inevitably needed so as to increase the machining efficiency. To fulfill such a task, this paper develops a robust active control method to mitigate the chatter dynamics of low radial immersion milling processes. The present approach increases the axial depth of cuts, and the improvement is inversely proportional to the radial immersion ratio. Finally, case studies are conducted to show the substantially enlarged stable region in the stability lobe diagram (SLD) spanned by spindle rotational speed and axial depth of cut. Thus, the method can be expected to improve the efficiency of milling processes.