Can we optimize machining parameters for interrupted milling? This paper presents a new stability theory for interrupted machining, focusing on scenarios where the ratio of time spent cutting to not cutting is small. It challenges traditional regenerative stability theory, predicting a doubling in the number of optimally stable spindle speeds as this ratio decreases. The assumptions underlying traditional regenerative stability theory become invalid for highly interrupted machining. Numerical simulations and experiments support the new theory. The authors anticipate that the theory will be relevant for selecting machining parameters in high-speed peripheral milling where the radial depth of cut is only a small fraction of the tool diameter. This research has implications for optimizing machining parameters in high-speed peripheral milling operations, leading to improved efficiency and reduced vibrations. The theory is particularly valuable for low radial immersion milling.
This paper, published in the Journal of Manufacturing Science and Engineering, contributes to the journal's focus on research that advances manufacturing processes. By developing a new stability theory for interrupted machining, the paper aligns with the journal's scope of improving the efficiency and precision of manufacturing operations. The work is particularly relevant to the journal's emphasis on optimizing machining parameters.