Flutter Stability Analysis Of Milling Process And Stiffness Field Modeling Of Multi-axis CNC Machining System

Under the require of high-speed CNC machining like typical aerospace thin-walled parts and complex surfaces with precision for auto mold, high-speedmilling stability and multi-axis machining system stiffness field modeling aremore important. In milling process, flutter can be caused by no rational millingparameters. Milling efficiency can be heavily restrained, machining accuracyreduced and tool wear happens all by flutter. Manufacturing equipment and cutterwith high performance do not equal high processing level. For avoiding flutter,researching physical model and simulating is an important premise in millingprocess dynamics. In addition, as the forced vibration exists, selecting no flutterprocess parameters in theory still can’t ensure the predestinated precision.In this article, the following works have been done for guiding millingprocess parameters selection:Firstly, Based on1DOF and2DOF milling dynamics model, these modelsare analyzed though full-discrete method and stability lobes with different DOFare obtained in order to predict effects of milling parameters on system stability.And, based on1DOF milling dynamics model, effects of axial force andgyroscopic effect on the stability in milling process are studied.3D stabilitylobes with varying stiffness and frequency based on research of single DOF bylinear interpolation. System stability can be analyzed and predicted.Secondly, the relationship between milling force coefficient and milling toolwear are advanced. Corresponding dynamics model is founded, and stability ispredicted by full-discrete method, the effect of different tool wear on millingstability is analyzed. Then, structure and parameters of multi-axis CNC machining system are analyzed. The influence of handle on system is introduced,and model for that is founded. By introducing the force ellipsoid, stiffnessperformance of the whole system at a state is decoupling analyzed. Complexstiffness field of tool position is predicted in CNC milling process.At last, software with predicting milling process dynamics is developed. It isfor predicting milling process stability and in order to guide the selection ofrational parameters in milling process.