High-efficiency smooth-surface high-chatter-stability machining of thin plates with novel face-milling cutter geometry

Abstract This paper presents a new technology to realize high-efficiency, smooth-surface, and high-chatter-stability machining of flexible thin plates with the proposed face-milling cutter geometry. Radius end mills are widely utilized for high-efficiency and smooth-surface machining, but they generally have low machining stability, i.e. chatter vibrations often occur. It is well known that the chatter stability depends on the structural flexibility and the cutting conditions, whereas it is less known that it strongly depends on the cutter geometry. In this study, a novel face-milling cutter geometry is proposed to improve chatter stability, especially for regenerative chatter, without sacrificing the high efficiency and the surface smoothness in radius end milling. The validity of the milling technology utilizing the proposed cutter geometry is verified analytically and experimentally.