Directional factor as the key factor for chatter free robotic milling of light alloys

Official URL: https://dx.doi.org/10.1016/j.cirp.2025.04.091

Robotic milling systems are increasingly used for light alloys and composites, but face challenges due to high dynamic flexibility of robots. A key issue is low-frequency chatter, linked to the robot's structural modes during high-speed operations. Therefore, this study deals with a dominant flexible mode with high tooth-passing frequencies, highlighting the influence of the directional factor. Negative directional factors can cause low-frequency chatter at high spindle speeds. Polar stability lobes show that optimal feed direction and radial engagement zones align with positive directional factors. The study shows that slotting operations assure a chatter free machining. Experimental validation confirms theoretical findings.