Improved prediction of stability lobes in milling process using time series analysis

In this paper, a new method is presented for prediction of cutting forces, surface texture and stability lobes in end milling operation based on time series analysis. in the approach, an equivalent damping ratio is defined for the cutting zone while the damping ratio of non-cutting zone is determined by experimental modal analysis. using correlation dimension criterion, the simulation and experimental force signals are compared to anticipate the value of process damping by assessing the variation of correlation dimension for both signals. the effect of cutter deflections and run out are taken into account. moreover, the stability lobes are predicted by considering the variation of process damping with cutting conditions. the feasibility of the proposed algorithm is verified experimentally for machining of aluminum 7075-t6. comparison of experiment results against simulation results indicates that the improved model can accurately predict cutting forces, surface texture and stability lobes for low radial immersion.