Effect of cutting conditions on the stability lobes for end milling process

Milling process will be dominated by multiple delays due to the effect of the cutter runout or the pitch angles of the cutter. In this paper, research efforts are focused on the dynamic behavior of milling processes under different cutting condition parameters such as different radial immersions, feed directions, feeds per tooth and helix angles. To improve the prediction accuracy of stability lobe, the combined influences of feed rate and cutter runout on the stability lobes are also taken into account. The basic principle of the method presented in one existing work is applied to examine the asymptotic stability trends for both down milling and up milling. Some new phenomena for certain combinations of cutting parameters are shown and explained in detail. It is found that as cutter runout occurs, feed per tooth, feed direction and cutter helix angle have great effects on the stability lobes.