Stability analysis for milling process

In this article, the stability of a milling process is studied by using a semi-discretization method. The model of the workpiece–tool system includes loss-of-contact effects between the workpiece and the tool and time-delay effects associated with the chip-thickness variation. In addition, feed-rate effects are also considered. The governing system of equations is a non-autonomous, delay-differential system with time-periodic coefficients. Stability of periodic orbits of this system is studied to predict the onset of chatter and numerical evidence is provided for period-doubling bifurcations and secondary Hopf bifurcations. Stability charts generated using the semi-discretization method are found to compare well with the corresponding results obtained through time-domain simulations.