Abstract
Chatter vibration for irregular tooth pitch end mill has been simulated using time domain cutting simulation based on the regenerative force and dynamic deflection model. The time domain cutting simulation program assumes that the vibration of end mill can be represented by using a lumped-parameter model with two degrees-of-freedom. Furthermore, it treats realistic nonlinearities accounting for the variation of uncut chip thickness, the changing of cutting force direction. In order to get a stability lobe diagram, the results of many time domain cutting simulations are evaluated by the average acceleration of the tool vibration during one rotation. Predicted stability lobes are compared with the results of cutting experiments, and they show that an irregular tooth pitch end mill can lead to an increase of stability. It is difficult to accomplish the quantitative agreement because of the assumptions in the modeling such as the constraint of tool motion and the treatment of process damping. But, the time domain cutting simulation can give the information to find an optimum cutting condition and a chatter free tool configuration.
