Abstract

In milling operations, cutters entering and exiting workpiece boundaries cause varying radial immersions and chip thicknesses. This generates aperiodic cutting forces that often induce vibrations and degrade surface quality. To address this, this study aims to accurately predict milling forces and surface profiles during these critical engagement and disengagement phases. An analytical approach was developed to estimate the changing distances between the cutting teeth and workpiece boundaries, enabling the precise calculation of the dynamic chip thickness as the cutter transitions through the material. Based on these dynamic calculations, milling forces and system responses were simulated. Experimental validation demonstrated a strong agreement between the simulated cutting forces, machined surface profiles, and real-world results. Notably, findings revealed that even cutting parameters deemed stable by traditional stability lobes can still trigger vibrations during these boundary transitions. Consequently, a novel parameter selection strategy is proposed to effectively prevent these transient vibrations, significantly enhancing the final surface finish. Ultimately, this comprehensive modelling framework provides a deeper understanding of the system dynamics throughout the entire milling process, offering high relevance for broader applications, such as optimising energy consumption, predicting tool wear, and improving machining parameter optimisation.

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