Prediction of Chatter Vibration by Means of a Model-Based Cutting Simulation System

This paper describes a system for predicting charter vibration in ad milling operation. The system estimates instantaneous cutting force vectors based on geometric models of a workpiece and a tool. The vibration of the tool induced by cutting forces is calculated by using a lumped-parameter model with two degrees of freedom. Considering changes in cutting volume due to tool deflections and regenerative effects, the numerical simulation of dynamic tool movement is conducted to check the occurrence of chatter vibration. To reduce the evaluation time, a simplified stability criterion is introduced to exclude apparently stable conditions. A number of cutting experiments were carried out to verify he effectiveness of the system.