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Experimental analysis of cutting edge effects on vibrations in end milling
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. Seco Tools, Fagersta, Sweden. (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
Lund University, Production and Materials Engineering, Lund, Sweden.
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. (PTW)ORCID iD: 0000-0003-0976-9820
2019 (English)In: CIRP - Journal of Manufacturing Science and Technology, ISSN 1755-5817, E-ISSN 1878-0016, Vol. 24, p. 66-74Article in journal (Refereed) Published
Abstract [en]

The ability to minimize vibrations in milling by the selection of cutting edge geometry and appropriate cutting conditions is an important asset in the optimization of the cutting process. This paper presents a measurement method and a signal processing technique to characterize and quantify the magnitude of the vibrations in an end milling application. Developed methods are then used to investigate the effects of various cutting edge geometries on vibrations in end milling. The experiments are carried out with five cutting edge geometries that are frequently used in machining industry for a wide range of milling applications. The results show that a modest protection chamfer combined with a relatively high rake angle has, for the most of cutting conditions, a reducing effect on vibration magnitudes. Furthermore, dynamics of a highly positive versus a highly negative cutting geometry is explored in time domain and its dependency on cutting conditions is presented. The results give concrete indications about the most optimal cutting edge geometry and cutting conditions in terms of dynamic behavior of the tool.

Place, publisher, year, edition, pages
2019. Vol. 24, p. 66-74
Keywords [en]
Milling, Acceleration, Cutting edge, Frequency spectrum, Rake angle, Chamfer
National Category
Manufacturing, Surface and Joining Technology
Research subject
ENGINEERING, Manufacturing and materials engineering; Production Technology
Identifiers
URN: urn:nbn:se:hv:diva-13735DOI: 10.1016/j.cirpj.2018.11.001ISI: 000460558000007Scopus ID: 2-s2.0-85057229226OAI: oai:DiVA.org:hv-13735DiVA, id: diva2:1297928
Funder
Knowledge Foundation
Note

Funders: Seco Tools

Available from: 2019-03-21 Created: 2019-03-21 Last updated: 2020-02-04Bibliographically approved
In thesis
1. 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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