Parameters optimization for chatter-free milling tool path based on spindle speed variation method

Existing methods orienting for optimizing cutting parameters in milling process with spindle speed variation (SSV) only optimally selected the axial depth of cut and only considered the acceleration constraint of spindle. This article proposes a systematic optimization method to obtain the best combination of multiple machining parameters (axial and radial depths of cut) and SSV's parameters (the ratio of variation amplitude and the ratio of variation frequency) so that the chatter-free milling tool path can be shortened. Both acceleration and jerk constraints of spindle are considered. A C³ continuous variable feedrate scheduling algorithm is used to eliminate the influence of spindle speed variation on feed per tooth, which is thus not required to treat as an optimization variable. The machining parameters of each iterative step are updated by following that the number of axial and radial cutting layers could be decreased. Discrete optimization method is combined with chatter stability analysis to solve the problem. A series of milling experiments verify that the proposed method can achieve the shortest tool path with chatter-free condition.