由於微銑削加工中未變形切屑厚度尺寸接近於微銑刀刀尖刃口半徑，造成加工時之切削力常數及犁切製程阻尼常數對刃口半徑變化相當敏感，也使得加工穩定葉瓣圖變異甚大。為了掌握刃口半徑之變化提高微銑削穩定葉瓣圖之預測準確性，本文首先建立從切削常數判別刃口半徑之方法，以及從顫震實驗判別切向與徑向製程阻尼常數之方法，進而探討刃口半徑對製程阻尼常數之影響。然而因刃口半徑量測不易，故建立線上刃口半徑判別模式，可實時量測刀具之刃口半徑。此模式利用已知刀具幾何與剪犁分離切削常數代入斜交切削理論中獲得正交刀傾角及摩擦角，搭配材料構成方程式求出流變應力及剪應力，及藉由犁切力理論獲得銑刀刃口半徑初估值。再將此刃口半徑與切削常數模式求得修正切削常數，修正切削常數與刃口半徑迭代後收斂即為所求刀具刃口半徑。同時本文建立兩種方法來判別製程阻尼常數，第一種為廣義線性預測模型，利用半離散法循特徵值邊界來模擬穩定葉瓣圖，建立兩反折點座標做為輸入，製程阻尼常數為輸出之模型，此模型可根據實驗求得反折點座標來預測製程阻尼常數。第二種方法利用顫震實驗判別製程阻尼常數，以動態補償法經由實驗分別建立系統微測力計及主軸加速規頻率響應函數，藉由此兩個頻率響應函數可將感測器量測到的力量及位移估測出刀尖瞬時力量及位移。從刀尖顫振動態力建立相量圖後可判別出製程阻尼常數。本文實驗以C36000快削黃銅搭配三把同型號刀具進行槽銑實驗，判別之刃口半徑與儀器量測結果誤差皆小於2μm。利用顫振實驗判別製程阻尼常數與廣義線性模型預測結果相近，且將判別之刃口半徑與製程阻尼常數結果相互比對，發現刃口半徑越小會造成製程阻尼常數上升使整體穩定葉瓣圖向高轉速區偏移，刃口半徑越大會造成製程阻尼常數下降造成葉瓣圖向低轉速區移動。

Because the undeformed chip thickness in micro-milling is close to the edge radius of micro-milling tool, the cutting and process damping constants are very sensitive to the change of tool edge radius, which also results in great variation of the stability lobe diagram. In order to find the variation of edge radius and improve the prediction accuracy of micro-milling stability diagram, a method of identifying the edge radius from cutting constant and method of identifying process damping constants from chatter experiments were established. However, it is not easy to measure the tool edge radius, so an on-line identifying model of edge radius is established. In this model, the orthogonal rake angle and friction angle are obtained by oblique cutting theory, and the flow stress and shear stress are calculated by the Johnson-Cook constitutive equation, and then the initial estimation of edge radius can be obtained by ploughing theory. Then the modified cutting constant can be obtained by using initial edge radius. The convergence of the modified cutting constants and the edge radius is the final edge radius. At the same time, two kinds of methods to predict process damping constants were established. The first is a Generalized Linear Model (GLM). The Semi-Discretization Method (SDM) is used to obtain the stability diagram along the eigenvalue boundary, and the GLM model with two turning point coordinates as input and process damping constants as output is established. The second method uses chatter experiment to identify the process damping constants, and establishes the frequency response function of the dynamometer and accelerometer through the dynamic compensation method. Then the process damping constants can be determined by phasor diagram. In this paper, C36000 free cutting brass was used with three tools of the same type. The differences between predicted edge radius and the ones measured by instrument were less than 2μm. The process damping constants identified by chatter experiments are similar to those predicted by the GLM. It is found that the smaller the edge radius is, the higher the process damping constants will be, causing the stability diagram shifted to higher spindle speed region. The bigger the edge radius is, the lower the process damping constants will be, causing the stability diagram shifted to lower spindle speed region.

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