Incorporating Stability, Surface Location Error, Tool Wear, and Uncertainty in the Milling Super Diagram

摘要

An improved milling "super diagram" is presented that graphically depicts not only stability and surface location error limitations to milling productivity, but also incorporates the influence of tool wear and uncertainty. Combinations of axial depth of cut and spindle speed that offer stable cutting conditions with an acceptable, user-defined surface location error level are identified by a gray-scale color coding scheme. The effect of tool wear is included through the force model coefficients used for process dynamics prediction. User beliefs about data and model accuracy are applied to identify safety margins relative to the deterministic boundaries. A numerical case study and experimental wear results are included.