Investigation on high-speed dry milling stability of high strength steel by compound Simpson prediction method

High-speed dry milling process for high-strength steel is widely used in the aerospace field, which can achieve good machining quality and accuracy while reducing the use of cutting fluid. However, unsuitable milling parameters can cause excessive vibration of the machine tool and even chattering of the milling system, which in turn affects the machining process. Thus, it is necessary to find the milling parameters boundaries of high-speed dry milling for high-strength steel. In this paper, based on the nonlinear milling force model, the regenerative effect and modal coupling are taken into account to establish a three-dimensional dynamic model for high-speed dry milling of high-strength steel, and the stability lobe diagram (SLD) is obtained by using the compound Simpson integration method (CoSIM), which is proved to be accurate and effective by numerical and experimental verification. The method fits using additional known time points and their responses, resulting in more accurate SLDs. Numerical validation results demonstrate that the method has higher prediction accuracy and convergence speed while maintaining higher computational rates. The study conducts experimental verification through multiple sets of high-speed dry milling experiments, demonstrating that the anticipated SLD findings are largely congruent with experimental outcomes. Consequently, the model and solution approach demonstrate significant potential in the selection of milling parameters.