Research on the influence of cutter overhang length on robotic milling chatter stability

Abstract Serial industrial robots are widely in demand in the field of large-scale component processing and manufacturing. However, the structure characteristic of serial robots makes it easy to generate chatter during milling and the overhang length of milling cutter has an important influence on the stability of robotic milling. Milling cutter overhang length refers to the length from the tip of the cutter to the protrusion of the spindle, to study the influence of milling cutter overhang length on the stability behavior of robotic milling, the modal parameters of milling cutter under different overhang length were obtained by hammer experiment, and its dynamic characteristics were analyzed. The stability behavior for robotic milling under different cutter overhang lengths was analyzed by using the stability lobe diagrams, and the stability lobe diagrams were verified by robotic milling experiments. The results show that the rigidity and natural frequency of milling cutter decrease with the increase of overhang length. There is a big gap between the stability lobe diagrams and the actual machining state when the cutter overhang length is short, and the low frequency vibration is easy to occur in the robotic milling process when the spindle speed is low, which is most probably because that the absorbed vibration energy by the cutter has been transferred to the robot body before the milling cutter vibrates. When the cutter overhang is increased and the feed direction is along the y-axis of the robot global coordinate system, the stability lobe diagrams by considering the multi-mode coupling effect is more consistent with the actual milling state.