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<p>To address poor machining quality and high experimental risks caused by regenerative chatter in milling hard-to-cut materials, this paper proposes a chatter stability analysis and measurement validation framework for crest-cut end mills, combining a differential geometric model with the full-discretization method (FDM). First, the crest-cut end mill is axially discretized into cutting elements, and a static milling force model is established by analytically reconstructing the cutting point geometry. Based on this, a two-degree-of-freedom dynamic equation considering time-delay effects is constructed, and the FDM is used to formulate the state transition matrix for rapid stability calculation. A measurement system comprising impact hammer testing, cutting force acquisition, and chatter stability testing was built. Side milling experiments show that the prediction error for three-directional average cutting forces is less than 5%, accurately reproducing the non-harmonic distortion of force signals induced by the crest-cut geometry. Stability lobe diagrams (SLDs) validation confirms that, compared with the semi-discretization method (SDM), this method improves prediction accuracy by 46% in the low-speed region and reduces computation time by 24.07% in the high-speed region while maintaining equivalent accuracy. A systematic study reveals the nonlinear modulation rules of crest-cut parameters on stability, quantifies an amplitude saturation threshold of approximately 0.3&#xa0;mm, and confirms that the inter-tooth phase shift is the decisive parameter for disrupting the regenerative feedback loop. This study provides a theoretical basis for the geometric parameter design of crest-cut end mills, and its excellent high-speed predictive performance can effectively reduce time-consuming and high-risk milling experiments.</p>

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Chatter stability prediction and experimental validation of crest-cut end mills based on the full-discretization method

  • 期刊论文

  • 发表日期：

    2026年7月10日

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  • Feihong Yun,
  • Peng Gao,
  • Kefeng Jiao,
  • Xiaoquan Hao,
  • Gang Wang,
  • Liquan Wang,
  • Yu Chen,
  • Yuming Du,
  • Peng Jia,
  • Xiangyu Wang

摘要

To address poor machining quality and high experimental risks caused by regenerative chatter in milling hard-to-cut materials, this paper proposes a chatter stability analysis and measurement validation framework for crest-cut end mills, combining a differential geometric model with the full-discretization method (FDM). First, the crest-cut end mill is axially discretized into cutting elements, and a static milling force model is established by analytically reconstructing the cutting point geometry. Based on this, a two-degree-of-freedom dynamic equation considering time-delay effects is constructed, and the FDM is used to formulate the state transition matrix for rapid stability calculation. A measurement system comprising impact hammer testing, cutting force acquisition, and chatter stability testing was built. Side milling experiments show that the prediction error for three-directional average cutting forces is less than 5%, accurately reproducing the non-harmonic distortion of force signals induced by the crest-cut geometry. Stability lobe diagrams (SLDs) validation confirms that, compared with the semi-discretization method (SDM), this method improves prediction accuracy by 46% in the low-speed region and reduces computation time by 24.07% in the high-speed region while maintaining equivalent accuracy. A systematic study reveals the nonlinear modulation rules of crest-cut parameters on stability, quantifies an amplitude saturation threshold of approximately 0.3 mm, and confirms that the inter-tooth phase shift is the decisive parameter for disrupting the regenerative feedback loop. This study provides a theoretical basis for the geometric parameter design of crest-cut end mills, and its excellent high-speed predictive performance can effectively reduce time-consuming and high-risk milling experiments.