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A short review on milling dynamics in low-stiffness cutting conditions: Modeling and analysis

The dynamic responses of milling system change the ideal trajectories of cutting teeth and therefore plays a critical role in determining the machining accuracy. The amplitude of cutting vibrations could reach tens of or even hundreds of micrometers in low-stiffness cutting conditions, for example, when milling thin-walled parts and/or using slender tools. Usually, moderate cutting parameters are utilized to avoid excessive cutting loads, strong milling chatter or large dynamic deflections, which however, significantly lowers the productivity. In spite of decades of study, it is still a challenge to accurately model, efficiently analyze, reliably monitor and precisely control the dynamic milling process in low-stiffness cutting conditions. In this paper, the recent advances and research challenges on dynamics modeling and response analysis are briefly reviewed.