Surface location error prediction and stability analysis of micro-milling with variation of tool overhang length

The stability of micro-milling has an important influence on the machined surface, and choosing proper machining parameters can effectively avoid machining process instability and dynamic error. The frequency response function (FRF) of micro-milling tool point varies with tool overhang lengths, and it affects stability lobe diagram (SLD) of the machining system. During the micro-milling process, the cutting thickness was divided into the shearing zone and the plowing zone. In the shearing zone, the cutting thickness was calculated with considering cycloidal tool path and dynamic cutting thickness. After the micro-milling force model was established, the receptance coupling substructure analysis (RCSA) and experimental modal analysis (EMA) were used to obtain the FRFs at the micro-milling tool point. The 2 three-dimensional diagrams, SLD and surface location error (SLE), were developed comprehensively by means of frequency domain method, and the flank micro-milling experiments were carried out. The validity of the three-dimensional SLD containing tool overhang length and the prediction model of SLE was verified by the experimental results, and surface topography was characterized to show the actual machining state. The experimental results show that, compared with SLE, the change of tool overhang length had more significant influence on SLD, and the chatter remarks were not very obvious on the bottom of the workpiece no matter whether the machining process was stable or not. In unstable region, chatter caused by cutting tool left marks on the machined surface. Under the condition of stable milling, a machined surface with smaller SLE and better topography was obtained. The 2 three-dimensional diagrams can provide good references for the selection of optimal tool overhang length and machining parameters comprehensively.