Summary
Imperfections of cutting tool manufacturing and clamping are regular problems in machining, which affect the chip formation kinematics, forced vibrations, quality of the machined surface, and tool wear. Such effects are often neglected in classical studies due to the modeling difficulties, measurement inaccuracies, and mathematical complexity. Misalignment of the milling cutter axes results in unequal force load on the cutting edges that changes the periodic forcing in the system, and hence changes the ideal cutter-workpiece-engagement. This effect is especially important when machining is performed at small radial immersions or with small feeds, where the cutting forces acting on the cutting edges can be drastically different due to the relatively small uncut chip thickness. In addition to this, the arising vibrations elevate the early fly-over effect leading to missed cuts during the operations. Nonlinear behavior is upraised by the forced vibrations and gives rise to multiple stable and unstable periodic solutions. The presented case study demonstrates that such effects can be strong in a certain domain of technological parameters, where new unexpected solutions and stability boundaries are formed.
