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Milling stability improvement through novel prediction and supression techniques

Milling stability improvement through novel prediction and supression techniques

Chatter is one of the main problems in today's milling processes. Theoretical models for the calculation of stability lobes are available to predict and prevent chatter. However, predictions done with milling stability models are not robust, and all too often the discrepancy between prediction and reality are significant.

There exist a variety of reasons for these deviations and they may be due to the sum of multiple effects. In the light of previous studies, the main errors are in the omission of double period lobes (flip lobes) and errors in the experimental determination of the dynamic parameters of the system using traditional experimental methods. This Thesis addresses these two main problems in prediction, providing new knowledge about the double period chatter and developing a new methodology for a more precise calculation of the dynamic response of the system.

However, an accurate prediction of the conditions leading to a stable milling process does not guarantee optimal machine use to maximize productivity, as required by today's production environment. For this reason, three new techniques are proposed for stabilisation of the process in which the used machining process is subject to influences from chatter.

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