Improvement of dynamic properties in milling by integrated stepped cutting

Die and mold machining usually necessitate employment of milling tools with long shanks. However, economic and technical design requirements often enforce low frequency structural vibration characteristics in work-pieces, especially in an area distanced from the tool holder. These structurally unstable designs pose a challenge for milling operations. The associated vibrations invariably reduce the quality of the work-piece produced and drastically increase average processing time and costs. This paper deals with cutting techniques used in face milling operations under semi-stable and unstable conditions. The strategy to use milling tools with integrated stepped cutting passes shows, that the use of smaller cutting ratios b/h, the chatter characteristics of the process could be significantly improved, thereby increasing the performance of the milling process.