Investigation of the milling stability based on modified variable cutting force coefficients

The cutting force signal distortion is caused by the dynamic characteristics of cutting force testing system. In order to handle this issue, we propose two improvements in the traditional inverse filtering technology. Firstly, we use three-spline interpolation method instead of the curve fitting method to fit the frequency response function of the test system which basically improves the accuracy of fitting. Secondly, the low-pass filter is added before the inverse filter to eliminate the influence of the high-frequency noise signal on the cutting force signal. We choose the cavity-free surface of outer covering parts of mold of automobile as research objects. The inverse filter dynamic compensation technology has been used to remove the influence of the dynamic characteristics of the test system and the high-frequency noise on the cutting force signal. The effectiveness of the proposed method is verified by relative milling experiments. Based on the experimentally measured forces after dynamic compensation, the modified cutting force coefficients are obtained using the average milling force method. The variation law of the cutting force coefficients with the axial depth, the radial width, and the feed rate is examined. Based on the modified variable cutting force coefficients, the 3D stability of the ball end milling cutter surface has been obtained using full-discretization approach. Combining the results from the cutting experiment and the nonlinear method, the stability prediction based on the modified variable cutting force coefficient can improve the prediction accuracy. The results provide theoretical support for the optimization of the machining process of the cavity-free surface of outer covering parts of mold of automobile.