The effects of end mill alignment errors on vibrations at high spindle speeds

Martin B. Jun, Shiv G. Kapoor, Richard E. Devor

Research output: Contribution to journalConference articlepeer-review


Dynamic cutting force and vibration model of an end mill process has been developed to investigate the effects of the tool alignment errors/process faults at high spindle speeds. The end mill is modeled as a Timoshenko beam to include the effects of shear deformation, rotary inertia, and gyroscopic moments that become significant at high speeds. The finite element method with cutting forces expressed as Fourier series has been used to solve the model. Experimental validation of the model has been performed, and the model is shown to predict cutting forces and end mill deflections within an average of 15%. Effects of process faults on the cutting forces and vibrations of the end mill have been examined. The results indicate that the tool alignment errors have significant effects on vibration at high spindle speeds.

Original languageEnglish (US)
Pages (from-to)9-16
Number of pages8
JournalTransactions of the North American Manufacturing Research Institute of SME
StatePublished - 2004
EventPapers Presented at NAMRC 32 - Charlotte, NC, United States
Duration: Jun 1 2004Jun 4 2004


  • Alignment error
  • High speed milling
  • Process fault
  • Vibration level

ASJC Scopus subject areas

  • Mechanical Engineering
  • Industrial and Manufacturing Engineering


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