Chatter stability of thin-walled part machining using special end mills

Machining thin-walled structures introduces challenges in terms of process stability due to the varying in -process workpiece dynamics. For the first time in the literature, this study compares the effectiveness and performance of standard, variable-pitch, and crest-cut tools on chatter suppression in milling thin-walled parts. The novel stability maps are generated based on varying stability limits caused by in-process workpiece dynamics. Using the obtained stability maps, the performance of different cutting strategies is compared con-sidering productivity and surface finish quality. The experimentally verified results demonstrate the superi-ority of crest-cut tools as a robust solution for overcoming chatter in thin-wall machining.(c) 2022 CIRP. Published by Elsevier Ltd. All rights reserved.