Identification and Modeling of Process Damping in Milling

In this study, a practical identification method for process damping is presented for milling, and the information obtained from identification is used for modeling purposes. In the proposed approach, the process-damping coefficients in x and y directions are identified directly from the experimental stability limits. Then, they are used in identification of the indentation constant through energy balance formulation. The identified indentation constant is further used in modeling of process damping and estimation of stability limit for different cutting conditions and tool geometries. Milling tools with two different types of flank geometries, namely, planar and cylindrical, are considered in this study. The predictions are verified by time-domain simulations and experimental results. It is shown that the presented method can be used for identification and modeling of process damping in milling to determine chatter-free cutting depths at relatively low cutting speeds.