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Even under a cutting condition in the stable area of the stability lobe, vibration may happen and leave mark on the machined surface in the process of a milling tool exits the workpiece, resulting in a non-neglected influence on the machining accuracy. This paper presents an analysis and control method for the milling tool exits the workpiece process, the method is generalized by estimating the chip thickness when a milling tool exits the workpiece, contributing to the predictions of milling forces and vibrations. Then a design method of the variable pitch cutter is proposed to suppress the vibration and improve the surface finish, enabling the control of cutting forces and displacements through decreasing the dynamic chip thicknesses. The developed methods are investigated analytically and experimentally, demonstrating their effects on analyzing and controlling the vibrations in the process of milling tool exiting the workpiece.
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