Document Type : Original Article


Department of Mechatronics Engineering, South Tehran Branch, Islamic Azad University, Tehran, Iran


Chatter is one of the most limitations that cause undesirable effect on improving productivity and part quality. In this paper, an experimental method has been used for analysing the effect of changing pitch in the indexable cutting tool in milling. For this purpose, the cutting forces of machining in three different directions were investigated and a comparison was made between tools with equal and unequal pitches. Milling of AISI 4140 has been performed with two different depths of cut (0.5&1mm) and the machining surface finish were examined. Furthermore, by using accelerometer sensors, the machining vibrations and machining forces by using dynamometer were measured. According to the findings, as well as the reduction of vibrations of machining about 50 %, machining forces reduction between 15% and 30% and surface finish improvement more than 200%were observed. In this regard, utilizing tools with different pitches leads to improvement in machining efficiency, reducing energy consumption, manufacture of high quality parts and it will ultimately reduce costs.


[1]     Quintana, G., Ciurana, J., and Teixidor, D., A New Experimental Methodology for Identification of Stability Lobes Diagram in Milling Operations, International Journal of Machine Tools and Manufacture, Vol. 48, No. 24, 2008, pp. 1637-1645, 10.1016/j.ijmachtools.2008.07.006.
[2]     Budak, E., An Analytical Design Method for Milling Cutters with Non Constant Pitch to Increase Stability, Part 1, Journal of Manufacturing Science and Engineering, Vol. 125, No. 1, 2003, pp. 29-34, 10.1115/1.1536655.
[3]     Budak, E., An Analytical Design Method for Milling Cutters with Non constant Pitch to Increase Stability, Part 2, Journal of Manufacturing Science and Engineering, Vol. 125, No. 1, 2003, pp. 35-38, 10.1115/1.1536656.
[4]     Sims, N. D., Fast Chatter Stability Prediction for Variable Helix Milling Tools, Proceedings of the Institution of Mechanical Engineers, Part C, Journal of Mechanical Engineering Science, Vol. 230, No. 1, 2016, pp. 133-144, 10.1177/0954406215585367.
[5]     Wang, Y., Wang, T., and Yu, Z., et al, Chatter Prediction for Variable Pitch and Variable Helix Milling, Shock and Vibration, Vol. 2015, pp. 1-9, 10.1155/2015/419172.
[6]     Otto, A., Rauh, S., and Ihlenfeldt, S., et al, Stability of Milling with Non-Uniform Pitch and Variable Helix Tools, Int J Adv Manuf Technol, Vol. 89, 2017, pp. 2613-2625, 10.1007/s00170-016-9762-2.
[7]     Suzuki, N., Kojima, T., and Hino, R., et al, A Novel Design Method of Irregular Pitch Cutters to Attain Simultaneous Suppression of Multi-Mode Regenerations, Procedia CIRP, Vol. 4, 2012, pp. 98-102, 10.1016/j.procir.2012.10.018.
[8]     Zatarain, M., Dombovari, Z., Stability Analysis of Milling with Irregular Pitch Tools by The Implicit Subspace Iteration Method, Int. J. Dynam. Control, Vol. 2, No. 1, 2014, pp. 26-34, 10.1007/s40435-013-0052-7.
[9]     Iglesias, A., Dombovari, Z., and Gonzalez, G., et al, Optimum Selection of Variable Pitch for Chatter Suppression in Face Milling Operations, Materials, Vol. 12, No. 112, 2018, pp. 1-22, 10.3390/ma12010112.
[10]  Altintaş, Y., Budak, E., Analytical Prediction of Stability Lobes in Milling, CIRP Annals, Vol. 44, No. 1, 1995, pp. 357-362, 10.1016/S0007-8506(07)62342-7.
[11]  Quintana, G., Ciurana, J., Chatter in Machining Processes, International Journal of Machine Tools and Manufacture, Vol. 51, No. 5, 2011, pp. 363-376, 10.1016/j.ijmachtools.2011.01.001.