Hybrid FE-experimental modeling of machine tool dynamics

Milling is one of the most important subtractive manufacturing processes. In the last decades the rising trend in the use of high speed machining (HSM) has presented new challenges for the machine tool manufacturers and users: modern milling processes have to combine high material removal rates with reduced geometrical errors and a fine surface finish. Due to the adoption of slender tools in HSM the process dynamics is the greatest constraint to the machine performance due to the occurrence of chatter vibrations. The improvement of the machine performance is carried out mainly thanks to time consuming experimental tests but, nowadays, the greater capabilities of numerical simulations open the possibility to the development of a milling process model fit for the optimization of the cutting conditions. In this paper will be presented the development of a smart numerical model to predict the machine tool dynamics in order to obtain a greater removal rate and chatter free cutting condition.