Micromilling can fabricate miniaturized components using micro-end mill at high rotational speeds. The analysis of machining stability in micromilling plays an important role in characterizing the cutting process, estimating the tool life, and optimizing the process. A numerical analysis and experimental method are presented to investigate the chatter stability in micro-end milling process with variable milling tool geometry. The schematic model of micromilling process is constructed and the calculation formula to predict cutting force and displacements is derived. This is followed by a detailed numerical analysis on micromilling forces between helical ball and square end mills through time domain and frequency domain method and the results are compared. Furthermore, a detailed time domain simulation for micro end milling with straight teeth and helical teeth end mill is conducted based on the machine-tool system frequency response function obtained through modal experiment. The forces and displacements are predicted and the simulation result between variable cutter geometry is deeply compared. The simulation results have important significance for the actual milling process.
Analysis and Prediction of Micromilling Stability with Variable Tool Geometry