Analysis of milling dynamics for simultaneously engaged cutting teeth

This paper investigates the stability of a milling process with simultaneously engaged teeth and contrasts it to prior work for a single tooth in the cut. The stability analyses are performed with the Chebyshev collocation method and the state-space TFEA technique. These analyses show that a substantially different stability behavior is observed. In addition, the stability lobes are shown to undergo rapid transitions for relatively small changes in the radial immersion ratio; these transitions are explained in terms of the specific cutting force profiles. The stable periodic motion of the tool was also investigated using a harmonic balance approach and a dynamic map created with the TFEA technique. The findings suggest that a large number of harmonics are required for the harmonic balance approach to obtain the correct solution.