Dynamic modeling of face milling process including the effect of fixture dynamics

Accurate prediction of the dynamic machining forces is essential in order to estimate the product and process quality and stability of the machining process. A comprehensive dynamic force model that takes into consideration the dynamic effects of the different machining process elements on the chip load was developed. The model considers the effect of cutter geometry, cutter initial position errors, workpiece geometry, machine tool dynamics, and workpiece/fixture dynamics. NURBS curves and surfaces are utilized for the geometric modeling of the machining process. FEA is used to model and analyze the workpiece/fixture dynamics. The effect of workpiece/fixture dynamics on the chip load and the machining process dynamics is investigated.