Investigation of milling stability based on a cutting force segmentation model

The chatter vibration is the major limiting factor for higher metal removal rates in milling process. This paper proposed an integral model of cutting force with helical cutter considering the sectional characteristics of cutting force. Based on the model, the variation law of the upper and lower limit angles of the cutting process under different radial cutting depths is analysed. The results show that the shape of cutting force for each tooth has a characteristic of three sections. Moreover, the process dynamic equation of thin-walled parts cutting is constructed based on the model. And, the stability lobe diagram is obtained by semi-discretization method. The time-domain simulations are carried out in different cutting parameters around the stable island to verify the correctness of the prediction method. The results show that the method has good ability to predict the cutting stability of cutters with helix angle.