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Cutter Exit Effects during Milling of Thin-walled Inconel 718
University West, Department of Engineering Science, Division of Mechanical Engineering. (PTW)
University West, Department of Engineering Science, Division of Mechanical Engineering. (PTW)
University West, Department of Engineering Science, Division of Mechanical Engineering. (PTW)
University West, Department of Engineering Science, Division of Production Engineering. (PTW)ORCID iD: 0000-0003-1408-2249
2012 (English)In: Advanced Materials Research, ISSN 1022-6680, E-ISSN 1662-8985, Vol. 590, 297-308 p.Article in journal (Refereed) Published
Abstract [en]

During milling of thin-walled components, chatter vibrations give rise to process issues. These include dimensional inaccuracy, damaged and scrap parts, and damaged cutting tools. This, in turn, leads to loss of production time with increasing cost as a consequence. This paper identifies the force profile during a single cut milling process. It focuses on the exit and post-exit behavior of the cut and discusses the process dynamics. The force profiles of various tool-to-workpiece positions are analyzed as regards the exit and post exit phases. A standard on-the-market cutter and a specially designed zero rake cutter are used in the investigation. Finally, a time-domain simulation of the force is performed and compared to the experimental results. The study concludes that a small change in exit angle may result in a considerable improvement in cutting behavior. In addition, the tool position should be chosen so that the cutter exits in the least flexible direction possible for the workpiece.

Place, publisher, year, edition, pages
Schweiz: Trans Tech Publications Inc., 2012. Vol. 590, 297-308 p.
Keyword [en]
Chatter vibrations, Thin wall, Inconel 718, Process stability, Exit angle
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
URN: urn:nbn:se:hv:diva-4686DOI: 10.4028/www.scientific.net/AMR.590.297Scopus ID: 2-s2.0-84870671318OAI: oai:DiVA.org:hv-4686DiVA: diva2:556878
Available from: 2012-12-21 Created: 2012-09-26 Last updated: 2016-11-21Bibliographically approved
In thesis
1. Strategies for Reducing Vibrations during Milling of Thin-walled Components
Open this publication in new window or tab >>Strategies for Reducing Vibrations during Milling of Thin-walled Components
2012 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Factors such as environmental requirements and fuel efficiency have pushed aerospace industry to develop reduced-weight engine designs and thereby light-weight and thin-walled components. As component wall thickness gets thinner and the mechanical structures weaker, the structure becomes more sensitive for vibrations during milling operations. Demands on cost efficiency increase and new ways of improving milling operations must follow.

Historically, there have been two “schools” explaining vibrations in milling. One states that the entry angle in which the cutting insert hits the work piece is of greater importance than the exit angle. The other states that the way the cutter leaves the work piece is of greater importance than the cutter entry. In an effort to shed some light over this issue, a substantial amount of experiments were conducted. Evaluations were carried out using different tools, different tool-to-workpiece offset positions, and varying workpiece wall overhang. The resultant force, the force components, and system vibrations have been analyzed.

The first part of this work shows the differences in force behavior for three tool-to-workpiece geometries while varying the wall overhang of the workpiece. The second part studies the force behavior during the exit phase for five different tool-to-workpiece offset positions while the overhang is held constant. The workpiece alloy throughout this work is Inconel 718.

As a result of the project a spread sheet milling stability prediction model is developed and presented. It is based on available research in chatter theory and predicts the stability for a given set of variable input parameters.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2012. 96 p.
Keyword
Milling, vibrations, chatter, stability, prediction, thin-wall, Inconel 718.
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-4955 (URN)978-91-7501-322-0 (ISBN)
Presentation
2012-12-07, KTH Royal Institute of Technolgy, Brinellvägen 68, Stockholm, 10:00 (English)
Opponent
Supervisors
Available from: 2012-12-28 Created: 2012-12-27 Last updated: 2015-10-02Bibliographically approved

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