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Influence of radial depth of cut on entry conditions and dynamics in face milling application
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. (PTW)ORCID iD: 0000-0003-3876-2361
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. (PTW)ORCID iD: 0000-0001-9331-7354
Seco Tools, Fagersta, Sweden.
Lund University ,Production and Materials Engineering, Lund Sweden.
Show others and affiliations
2017 (English)In: Journal of Superhard Materials, ISSN 1063-4576, Vol. 39, no 4, p. 259-270Article in journal (Refereed) Published
Abstract [en]

The choice of milling cutter geometry and appropriate cutting data for certain milling application is of vital importance for successful machining results. Unfavorable selection of cutting conditions might give rise to high load impacts that cause severe cutting edge damage. Under some circumstances the radial depth of cut in combination with milling cutter geometry might give unfavorable entry conditions in terms of cutting forces and vibration amplitudes. This phenomenon is originated from the geometrical features that affect the rise time of the cutting edge engagement into workpiece at different radial depths of cut. As the radial depth of cut is often an important parameter, particularly when machining difficult-to-cut materials, it is important to explore the driving mechanism behind vibrations generation. In this study, acceleration of the workpiece is measured for different radial depths of cut and cutting edge geometries. The influence of the radial depth of cut on the dynamical behavior is evaluated in time and frequency domains. The results for different radial depths of cut and cutting geometries are quantified using the root mean square value of acceleration. The outcome of this research study can be used both for the better cutting data recommendations and improved tool design.

Place, publisher, year, edition, pages
New York: Allerton Press , 2017. Vol. 39, no 4, p. 259-270
Keywords [en]
milling entry, radial depth, cutting edge, cutting force, vibration
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology; ENGINEERING, Manufacturing and materials engineering
Identifiers
URN: urn:nbn:se:hv:diva-11769DOI: 10.3103/S1063457617040062ISI: 000409936100006Scopus ID: 2-s2.0-85029210912OAI: oai:DiVA.org:hv-11769DiVA, id: diva2:1151054
Funder
Knowledge FoundationAvailable from: 2017-10-20 Created: 2017-10-20 Last updated: 2020-01-13Bibliographically approved
In thesis
1. Analysis of entry phase in intermittent machining
Open this publication in new window or tab >>Analysis of entry phase in intermittent machining
2018 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Cutting forces and vibrations are essential parameters in the assessment of a cutting process. As the energy consumption in the machining process is directly affected by the magnitude of the cutting forces it is of vital importance to design cutting edges and select process conditions that will maintain high tool performance through reduced energy consumption. The vibrations are often the cause of poor results in terms of accuracy, low reliability due to sudden failures and bad environmental conditions caused by noise. The goal of this work is to find out how the cutting edge and cutting conditions affect the entry conditions of the machining operation. This is done utilizing experimental methods and appropriate theoretical approaches applied to the cutting forces and vibrations. The research was carried out through three main studies beginning with a force build-up analysis of the cutting edge entry into the workpiece in intermittent turning. This was followed by a second study, concentrated on modelling of the entry phase which has been explored through experiments and theory developed in the first study. The third part was focused on the influence of the radial depth of cut upon the entry of cutting edge into the workpiece in a face milling application. The methodology for the identification of unfavourable cutting conditions is also explained herein. Important insights into the force build-up process help addressing the correlation between the cutting geometries and the rise time of the cutting force. The influence of the nose radius for a given cutting tool and workpiece configuration during the initial entry is revealed. The critical angle i.e. the position of the face milling cutter that results in unfavourable entry conditions has been explained emphasizing the importance of the selection of cutting conditions. Finally, the theoretical methods utilized for the evaluation of the role of cutting edge geometry within entry phase dynamics has been explored. This has revealed the trends that are of interest for selection of cutting conditions and cutting edge design.

Place, publisher, year, edition, pages
Trollhättan: University West, 2018. p. 74
Series
Licentiate Thesis: University West ; 21
Keywords
Entry; Cutting force; Cutting edge geometry; Acceleration
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology; ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-12255 (URN)978-91-87531-80-4 (ISBN)978-91-87531-79-8 (ISBN)
Presentation
2018-04-19, 10:00 (English)
Supervisors
Available from: 2018-04-19 Created: 2018-04-16 Last updated: 2019-10-23
2. Edge Geometry Effects on Entry Phase by Forces and Vibrations
Open this publication in new window or tab >>Edge Geometry Effects on Entry Phase by Forces and Vibrations
2020 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Intermittent machining is in general strongly related to the large impacts in the entry phase and related vibrations. The influence of the impact forces and vibrations on the cutting process is dependent on workpiece material, structural properties of the tool-workpiece system, cutting edge geometries and cutting parameters. Cutting forces adopt generally a periodic behaviour that gives rise to forced vibrations. In addition, self-induced vibrations may arise because of lowrigidity and insufficient damping in the tool-workpiece system at specific cutting parameters. The ability of the cutting tool to carry the loads during the entry phase and minimize the vibrations is often the key parameter for an effective machining operation.This research work is based on the experiments, analytical studies and modelling. It was carried out through six main studies beginning with a force build-up analysis of the cutting edge entry into the workpiece in intermittent turning. This was followed by a second study, concentrated on modelling of the entry phase which has partly been explored through experiments and theory developed in the first study.

The third part was focused on the influence of the radial depth of cut upon the entry of the cutting edge into the workpiece in a face milling application. The methodology for the identification of unfavourable radial depth of cut is also addressed herein. Next, effects of the cutting edge on the vibrations in an end milling application were investigated. This study was related to a contouring operation with the maximum chip thickness in the entry phase when machining steel, ISO P material.

The results of this work provide some general recommendations when milling this type of workpiece material. After that, the focus was set on the dynamic cutting forces in milling. The force developments over a tooth engagement in milling showed to be strongly dependent on the cutting edge geometry. A significant difference between highly positive versus highly negative geometry was found.

The implication of this phenomena on the stress state in the cutting edge and some practical issues were analysed. Finally, the role of the helix angle on the dynamic response of a workpiece was investigated. The modelling technique using force simulation and computation of the dynamic response by means of modal analysis was presented. Extensive experimental work was conducted to compare the modelling and experimentally obtained results. The modelling results showed a similar trend as the experimental results. The influence of helix angle on the cutting forces and the dynamic response was explained in detail.The research conducted in this work contributes to the deeper understanding of the influence of the cutting edge geometry and the cutting parameters on the force build up process during the entry phase. The presented studies investigate the force magnitudes, force rates and dynamic behaviour of the tools and workpieces when machining at the challenging entry conditions. The methodologies applied are focused on the physical quantities as forces and vibrations rather than the experimental studies that evaluate tool life. The methods and results of the research work are of great interest for the design of the cutting tools and optimization of the cutting processes.

Place, publisher, year, edition, pages
Trollhättan: University West, 2020. p. 133
Series
PhD Thesis: University West ; 32
Keywords
Entry; Cutting force; Cutting edge geometry; Acceleration
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology; ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-14852 (URN)978-91-88847-46-1 (ISBN)978-91-88847-45-4 (ISBN)
Public defence
2020-02-06, C208, 10:00 (English)
Opponent
Supervisors
Available from: 2020-01-15 Created: 2020-01-13

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Agic, AdnanEynian, MahdiBeno, Tomas

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