Chatter is one of the major problems in today’s milling processes. Theoretical models to calculate stability lobes are used to predict and avoid chatter onset. However, current predictions are not accurate enough and significant deviations between predicted and experimentally observed stability limits have been reported.The causes for these deviations are diverse and can be the result of the sum of multiple effects. According to previous works, main errors in stability prediction are related to lack of knowledge about double period instability (flip lobes) and inappropriate determination of dynamic parameters through standard experimental characterization techniques. This Thesis deals with these two problems that affect accurate chatter prediction, contributing with new knowledge and calculation methods for double period type lobes and developing a new methodology for a more accurate dynamic response identification. Nevertheless, an accurate chatter stability prediction does not necessarily imply an optimum use of the machine to maximize productivity, as it is required in current production environments. For this reason, three novel process stabilization techniques are proposed for those cases in which the designed machining process is subject to chatter vibrations.
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