Chatter stability of thin-walled part machining using special end mills

Machining thin-walled structures introduces challenges in terms of process stability due to the varying in-process workpiece dynamics. For the first time in the literature, this study compares the effectiveness and performance of standard, variable-pitch, and crest-cut tools on chatter suppression in milling thin-walled parts. The novel stability maps are generated based on varying stability limits caused by in-process workpiece dynamics. Using the obtained stability maps, the performance of different cutting strategies is compared considering productivity and surface finish quality. The experimentally verified results demonstrate the superiority of crest-cut tools as a robust solution for overcoming chatter in thin-wall machining.