A Comprehensive Review of Time-Domain Approaches for Chatter Dynamics and Forced Vibration Analysis in Thin-Walled Milling

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Dheeraj S. Lengare, D. R. Pangavhane

Abstract

Chatter is a prevalent self-excited vibration phenomenon that occurs in most milling procedures and substantially affects surface quality, tool life, and productivity. This paper discusses time-domain methods for modeling chatter dynamics and forced vibration in thin-walled milling, mainly focusing on prediction, detection, and control techniques. To deal with the chatter phenomenon, theoretical factors affecting chatter, such as process damping, tool run-out, and gyroscopic effects, are discussed to gain insight into their influence on stability prediction. This paper reviews models for milling force prediction with the prospective application of these models to thin-walled structures. It further questions the established experimental methods, such as finite element modal analysis or structural coupling, for obtaining frequency response functions of workpieces and tools. Advances and performances of hardware in the loop simulation study deal with the reflection of mirror-milling technology development aimed at application to performing thin-walled part components. The review discusses the root causes of chatter and provides the path for future work to further improve prediction accuracy and suppression methodologies. This contributes to the sustainable planning of successful thin-walled milling processes with improved characteristics and machine output.

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