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Machine tool vibrations impose severe limitations on industry. Recent progress in solving for the stability behavior of delay differential equations and in modeling milling operations with time delay differential equations has provided the potential to significantly reduce the aforementioned limitations. However, industry has yet to widely adopt the current academic knowledge due to the cost barriers in implementing this knowledge. Some of these cost prohibitive tasks include time-consuming experimental cutting tests used to calibrate model force parameters and experimental modal tests for every combination of tool, tool holder, tool length, spindle, and machine. This paper introduces an alternative approach whereby the vibration behavior of a milling tool during cutting is used to obtain the necessary model parameters for the common delay differential equation models of milling. • Method to estimate milling model parameters from experimental time series. • Estimated parameters used to predict stability chart for range of cutting conditions. • Stability predictions show close match with experimental results. • Extends the spectral element method to incorporate steady-state vibration. • Automated approach for instrumented milling that makes manual modal test unnecessary. [ABSTRACT FROM AUTHOR]

In this work we present a quantitative measurement-based method to describe the stability behaviour of a periodic dynamical system. In-process response for impulse during milling is analysed to provide operational stability prediction. The proposed method combines chatter detection techniques with the theory of time-periodic delay differential equations applied for general milling operations. Signal processing based on dynamic modal decomposition approach not only presents qualitative properties (like stability/instability) but also quantifies a measure of stability through the determination of the Floquet multipliers. The corresponding monodromy operator of the milling process is approximated from the measured system's response during machining operation. By changing the technological parameters, the variation of the modulus of the Floquet multipliers can be monitored. The stability limit can precisely be interpolated with the unitary multiplier; furthermore, the stability limit can be extrapolated while the manufacturing parameters remain in the chatter-free region. The presented approach is validated by numerical results and laboratory tests. • Measurement-based method to quantify stability of milling operation. • In-process impulse response is analysed to provide operational stability prediction. • It combines chatter detection techniques with the theory of time-periodic systems. • Extrapolation of stability limit opens ways for efficient cutting parameter optimization. • Results are supported by theoretical, numerical and experimental parts. [ABSTRACT FROM AUTHOR]