Abstract
Chatter vibration is an important topic in the machining process, especially for the small-diameter ball-end mills or the thin wall workpieces. This research focuses on the influence of tool inclination on chatter vibration in ball-end milling. Initially, the stability region was predicted by a stability lobe diagram. Modal parameters and cutting force coefficients were obtained by hammering test and milling test. Milling experiments with different tool inclination were conducted for a cylindrical workpiece using a ball end mill. Acceleration signals of milling experiments were measured by a three-axis accelerometer and analyzed by Fast Fourier Transform (FFT). The tool-workpiece contact was geometrically identified with considering the position of tool-tip center. The results showed damping effect of the tool-tip center in the cut area. Furthermore, the chatter occurred when the tool-tip center does not contact with the workpiece under the unstable region of stability lobe diagram.
