Nonlinear dynamics of milling processes.

*(English)*Zbl 1056.74026From the summary: We investigate dynamics and stability of milling operations with cylindrical end mills. A unified-mechanics-based model, which allows for both regenerative effects and loss-of-contact effects, is presented for study of partial-immersion, high-immersion and slotting operations. Reduced-order models that can be used for certain milling operations such as full-immersion operations and finishing cuts are also presented. On the basis of these models, the loss of stability of periodic motions of the workpiece-tool system is assessed by using Poincaré sections, and the numerical predictions of stable and unstable motions are found to correlate well with the corresponding experimental observations. Bifurcations experienced by periodic motions of the workpiece-tool system with respect to quasi-static variation of parameters such as axial depth of cut are examined and discussed.