Predicting high-speed milling dynamics using stereolithography

Abstract

Stereolithographic (SL) models have been successfully utilized during product development and the early stages of process design. In this research, SL models were utilized to predict the natural frequencies of high-speed cutting tools. Most common practices utilize theoretical or numerical methods to evaluate tool designs by using simplifying assumptions. However, these results may fail to accurately predict stability limits of the machining system. This research developed a proactive approach for evaluating tool design, which minimizes the risk of ordering the wrong tool and sacrificing the most economic machining condition. Experiments have indicated that SL models correlate well with test results performed on actual machining systems. Consequently, SL models of selected tool designs were constructed and utilized to predict the dynamic characteristics and the stability limits of the machining system. Using stereolithographic models, practitioners can generate stability lobe diagrams and study tool design alternatives before producing or ordering a required tool.