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Dynamic effects on cutting forces with highly positive versus highly negative cutting edge geometries
Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT). Seco Tools, Fagersta, Sweden. (PTW)ORCID-id: 0000-0003-3876-2361
Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT). (PTW)ORCID-id: 0000-0001-9331-7354
Lund University, Production and Materials Engineering, Lund, Sweden.
Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT). (PTW)ORCID-id: 0000-0003-0976-9820
2019 (Engelska)Ingår i: International Journal on Interactive Design and Manufacturing, ISSN 1955-2513, E-ISSN 1955-2505, Vol. 13, nr 2, s. 557-565Artikel i tidskrift (Refereegranskat) Published
Abstract [en]

Understanding the influence of the cutting edge geometry on the development of cutting forces during the milling process is of high importance in order to predict the mechanical loads on the cutting edge as well as the dynamic behavior on the milling tool. The work conducted in this study involves the force development over the entire engagement of a flute in milling, from peak force during the entry phase until the exit phase. The results show a significant difference in the behavior of the cutting process for a highly positive versus a highly negative cutting edge geometry. The negative edge geometry gives rise to larger force magnitudes and very similar developments of the tangential and radial cutting force. The positive cutting edge geometry produces considerably different developments of the tangential and radial cutting force. In case of positive cutting edge geometry, the radial cutting force increases while the uncut chip thickness decreases directly after the entry phase; reaching the peak value after a certain delay. The radial force fluctuation is significantly higher for the positive cutting edge geometry. The understanding of such behavior is important for modelling of the milling process, the design of the cutting edge and the interactive design of digital applications for the selection of the cutting parameters.

Ort, förlag, år, upplaga, sidor
2019. Vol. 13, nr 2, s. 557-565
Nyckelord [en]
Milling, Cutting force, Cutting edge geometry, Frequency spectrum, RMS
Nationell ämneskategori
Bearbetnings-, yt- och fogningsteknik
Forskningsämne
TEKNIK, Produktions- och materialteknik; Produktionsteknik
Identifikatorer
URN: urn:nbn:se:hv:diva-13302DOI: 10.1007/s12008-018-0513-5ISI: 000468115700013Scopus ID: 2-s2.0-85058211299OAI: oai:DiVA.org:hv-13302DiVA, id: diva2:1276414
Forskningsfinansiär
KK-stiftelsen
Anmärkning

Funders: Seco Tools

Tillgänglig från: 2019-01-08 Skapad: 2019-01-08 Senast uppdaterad: 2020-02-03Bibliografiskt granskad
Ingår i avhandling
1. Edge Geometry Effects on Entry Phase by Forces and Vibrations
Öppna denna publikation i ny flik eller fönster >>Edge Geometry Effects on Entry Phase by Forces and Vibrations
2020 (Engelska)Doktorsavhandling, sammanläggning (Övrigt vetenskapligt)
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.

Ort, förlag, år, upplaga, sidor
Trollhättan: University West, 2020. s. 133
Serie
PhD Thesis: University West ; 32
Nyckelord
Entry; Cutting force; Cutting edge geometry; Acceleration
Nationell ämneskategori
Bearbetnings-, yt- och fogningsteknik
Forskningsämne
Produktionsteknik; TEKNIK, Produktions- och materialteknik
Identifikatorer
urn:nbn:se:hv:diva-14852 (URN)978-91-88847-46-1 (ISBN)978-91-88847-45-4 (ISBN)
Disputation
2020-02-06, C208, 10:00 (Engelska)
Opponent
Handledare
Tillgänglig från: 2020-01-15 Skapad: 2020-01-13

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