Modelling and analysis of the impact of chatter and cutting forces on machined surfaces in milling

The Chatter vibrations are a critical issue in milling, affecting workpiece quality and potentially damaging machines. This study analyzes the causes of chatter and proposes preventive methods. After reviewing the existing research, the transfer function is analyzed using an orthogonal cutting model, highlighting its evolution concerning system stability. A dynamic stability map is developed to help select optimal spindle speeds and cutting depths. Experiments using an innovative chatter detection device, based on noise analysis, demonstrate real-time identification of chatter, enhancing operational stability. The second part focuses on modeling cutting forces, essential for optimizing machining conditions and mitigating vibrations. A thermo-mechanical approach is applied using the Abaqus simulator and the Arbitrary Lagrangian-Eulerian (ALE) method to study the impact of cutting conditions on mechanical stress and temperature at the tool-workpiece interface. The results show that cutting parameters significantly influence both stress distribution and thermal behavior. By combining real-time chatter detection with precise cutting force modeling, this study offers an effective way to optimize machining parameters, improving process stability and operational efficiency. This integrated approach enhances the accuracy of predictive models and contributes to better machining outcomes.