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Stability-based selection of cutting parameters to increase material removal rate in high-speed machining process

The reasonable selection of cutting parameters is of great significance to improve the productivity in high-speed machining process. In this article, a stability-based selection method of cutting parameters is proposed to increase material removal rate in high-speed machining process. First, the coupled dynamics of the high-speed spindle system and machining process is modeled. Then, the interaction mechanism between the spindle-tool system and the cutting process is investigated. Based on the process stability and surface quality of workpiece, a cutting parameter selection method is proposed from the perspective of machining stability. In order to select reasonable spindle speed and depth of cut, the lower bound of chatter stability lobe diagram and surface finish are taken as constraints, and the maximum material removal rate is set as the target. The proposed method is applied to the machining of the front face of a gearbox cover, which is made of Aluminum-7050. The axial depth of cut and spindle speed are chosen reasonably with the increase in machining efficiency by about 133%.