Chatter maps for process design of powertrain components

During rough machining operations of powertrain components, chatter vibrations may occur on the edges of flexible structures. This paper presents a numerical method, based on the finite element method and Tlusty's theory, which gives a chatter map of the machined surface. Each map point represents the greatest depth of cut leading to unconditionally stable cut. Each value depends on the structural damping, the cutting stiffness and the local static stiffness, which is computed using conventional linear elastic FEA. Chatter maps offer a convenient and effective decision support system for robust process design. As a case study, the rough milling operation of a crankcase deck face with a two-stage cutter is presented.