Prediction of Chatter Stability in Bull-Nose End Milling of Thin-Walled Cylindrical Parts Using Layered Cutting Force Coefficients

During the bull-nose end milling operations of thin-walled structures, chatter usually occurs and adversely affects cutter performance, finished surface quality, and production efficiency. To accurately predict chatter stability, a suitable dynamic model with effective system parameters is required. In this article, a three-degree-of-freedom (3-DOF) dynamic model is developed to analyze the milling stability of the thin-walled cylinders, in which the dynamics of the bull-nose end mill along the x-axis and y-axis directions and the dynamic of the workpiece along the z-axis direction are taken into account. Then, the cutter-workpiece engagement (CWE) is extracted by employing a slice-intersection-based approach. And the layered cutting force coefficients are identified by considering the influences of varying cutter diameters on the cutting speed. Thereafter, the semi-discretization method (SDM) is adopted to compute the stability lobe diagram (SLD). In the end, a group of milling tests are carried out on a thin-walled cylinder to validate the accuracy and reliability of the proposed model, and the results show that the model predictions agree well with the experimental data.