Milling stability considering multiple effects and variable rotational speed milling chatter control

One of the most frequent barriers to decreasing the surface quality of workpieces during milling machining is chatter, and the accuracy of chatter prediction is directly impacted by the number of effects that are considered during the modeling of the milling process. Previous researchers have studied the impact of chatter suppression on the spindle variable rotational speed method in the milling model while considering various effects. The variable rotational speed waveforms primarily focus on the fundamental waveform or a composite of sine waveforms. The study presents a novel method for variable speed control, utilizing a waveform that combines sine and triangular waveforms. The effect of this method on chatter suppression is investigated in a milling dynamics model that considers regenerative, modal coupling, and process damping effects. This novel method overall improves milling stability significantly. The accuracy of the novel method is verified by simulation and experiment. Next, the analysis focuses on the influence of immersion rate, spindle modulation coefficients, and phase difference on stability, based on stability prediction. The choice of these parameters has a direct influence on the ability to suppress chatter.