The role of tool presetting in milling stability uncertainty

This paper describes the relationship between presetter tool extension length and diameter measurements, the tool point frequency response function (FRF), and milling stability. Three scenarios are considered: 1) the tool extension from the holder face is controlled during setup and measured by the presetter for validation; 2) the tool extension length from the holder face is not controlled during setup and measured to update the tool information in the part program; and 3) the measured extension length is used to update the stability boundary prediction and corresponding operating parameters in the part program. Example presetting results are provided to establish the associated measurement uncertainty. Next, the receptance coupling substructure analysis (RCSA) technique is used within a Monte Carlo simulation to establish the tool point FRF uncertainty as a function of the tool extension length and diameter uncertainty. Finally, the distribution in the tool point FRF is propagated to uncertainty in the milling stability limit. Each of the three scenarios is evaluated to understand their implications for milling stability.