Study on Dynamic Simulation and Cutting Parameters Optimization on Complex Cutting Conditions Milling Process

Considering the deficiency in cutting conditions optimization of milling process, based on the dynamic modeling of milling process, a dynamic simulation software of complex cutting conditions milling process was developed successfully in Matlab-VB.net hybrid environment. On the basis of measurement of machining system's dynamics and corresponding experimental modal analysis results, the simulation system can provide some physical parameters such as dynamic cutting forces, spindle power, torque, vibrations of tool and workpiece, as well as stability lobe diagram (SLD) of a complex cutting conditions milling process, in which both a linear or circular tool-path and a cutting tool with complicated geometry can be used. According to the corresponding dynamic simulation results, the cutting conditions optimization can be accomplished effectively, so it can provide some instructive directions for the CNC operators. The major functions of the simulation system have been validated successfully in workshop application.