Simulation of the NC Milling Process for the Prediction and Prevention of Chatter

Odendahl, S.1, a; Joliet, R.1, b; Ungemach, E.1; Zabel, A.1, c; Kersting, P.1, d; Biermann, D.1, e

Institut für Spanende Fertigung, Technische Universität Dortmund, Baroper Str. 303, 44227 Dortmund

a); b); c); d); e)


The main goal in the design of milling processes for components in the aerospace industry is the optimization of productivity while maintainig process stability. These two goals can be conflicting, especially if long tools are required, which are particularly susceptible to vibrations. In order to reduce the number of costly experiments, simulation-based approaches can be used to evaluate generated NC programs beforehand. In this paper, a modeling approach for the detailed simulation of engagement conditions, process forces, and dynamic tool behavior is used to detect instable process conditions. Additionally, an algorithm is presented to change the axial immersion in order to avoid regenerative chatter during milling. To demonstrate the effectiveness of the simulation approach and of the compensation strategy, a comparison is shown between experimental and simulated results and between the workpiece generated by the original and the optimized NC programs.


Milling, simulation, modeling, chatter


In: New Production Technologies in Aerospace Industry, Denkena, B. (Hrsg.), Springer Verlag, Cham, 2013, ISBN 978-3-319-01963-5, Kapitel 3, S. 19-25