Two of the most common challenges to milling productivity are tool/workpiece chatter and tool wear. The challenge for process engineers is to select the proper machining parameters to minimize both chatter and tool wear for the most efficient production of accurate parts.
This presentation describes modeling/simulation processes that generate stability lobe diagrams to identify the most efficient spindle speeds and axial depths for specific applications and avoid costly, time-consuming trial-and-error adjustments to machining parameters. For titanium machining, where surface speed is limited by tool wear, stability lobe diagrams can be used to maximize spindle speeds, which can increase the chatter-free axial depth of cut to maximize productivity while preventing unnecessary tool wear.