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  • 1.
    Agic, Adnan
    et al.
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. Seco Tools, Fagersta, Sweden.
    Eynian, Mahdi
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Ståhl, J. -E
    Lund University, Production and Materials Engineering, Lund, Sweden.
    Beno, Tomas
    University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Experimental analysis of cutting edge effects on vibrations in end milling2019In: CIRP - Journal of Manufacturing Science and Technology, ISSN 1755-5817, E-ISSN 1878-0016, Vol. 24, p. 66-74Article in journal (Refereed)
    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.

  • 2.
    Bonilla Hernández, Ana Esther
    et al.
    University West, Department of Engineering Science, Research Enviroment Production Technology West.
    Beno, Tomas
    University West, Department of Engineering Science, Division of Manufacturing Processes. University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Repo, Jari
    University West, Department of Engineering Science, Division of Manufacturing Processes.
    Wretland, Anders
    GKN Aerospace Engine Systems AB, Trollhättan, Sweden.
    Integrated optimization model for cutting data selection based on maximal MRR and tool utilization in continuous machining operations2016In: CIRP - Journal of Manufacturing Science and Technology, ISSN 1755-5817, E-ISSN 1878-0016, Vol. 13, p. 46-50Article in journal (Refereed)
    Abstract [en]

    The search for increased productivity can be interpreted as the increase of material removal rate (MRR). Namely, increase of feed, depth of cut and/or cutting speed. The increase of any of these three variables, will increase the tool wear rate; therefore decreasing its tool life according to the same tool life criteria. This paper proposes an integrated model for efficient selection of cutting data for maximal MRR and maximal tool utilization. The results show that, it is possible to obtain a limited range of cutting parameters from where the CAM Programmer can select the cutting data assuring both objectives.

  • 3.
    Eynian, Mahdi
    University West, Department of Engineering Science, Division of Manufacturing Processes.
    Prediction of vibration frequencies in milling using modified Nyquist method2015In: CIRP - Journal of Manufacturing Science and Technology, ISSN 1755-5817, E-ISSN 1878-0016, Vol. 11, no November, p. 73-81Article in journal (Refereed)
    Abstract [en]

    Study of the vibration frequencies at different cutting conditions is an alternative to the use of impact hammer test for identification of natural frequencies of the machining structure and calculation of stability lobe diagrams. Vibration frequencies not only depend on the natural frequencies of the structure, but also they are dependent on the spindle speed, damping ratio of the structure and the depth of cut. Ignoring these additional parameters would lead to errors in identification of the natural frequencies of the system and considerable deviation of the calculated stability lobe diagrams from actual cutting tests. In this study modified Nyquist method is used to investigate the effects of spindle speed, depth of cut and damping ratio of the structure on vibration frequencies. The quality of frequency prediction is compared to linear and nonlinear time domain simulations and machining experiments.

  • 4.
    Repo, Jari
    et al.
    University West, Department of Engineering Science, Division of Mechanical Engineering.
    Pejryd, Lars
    University West, Department of Engineering Science, Division of Mechanical Engineering.
    Beno, Tomas
    University West, Department of Engineering Science, Division of Mechanical Engineering. University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing.
    Measurement method for the identification of individual teeth in milling operations2012In: CIRP - Journal of Manufacturing Science and Technology, ISSN 1755-5817, E-ISSN 1878-0016, Vol. 5, no 1, p. 26-32Article in journal (Refereed)
    Abstract [en]

    Internal sensors already available in the machine tools may prove to be an interesting approach to monitor the machining process. Accurate determination of the position of the individual tooth on a milling cutter is important to be able to correlate the measured responses from the machine tool position encoders to the tooth or teeth that may be the cause of the response.

    The aim of the work presented in this paper is to develop a measurement method to identify the individual tooth on a milling cutter by their angular position relative to a specified 0-degree direction. If the lower and upper bounds of the cutting zone are known, together with the actual spindle position and the starting time of the cut, it will be possible to track and identify which teeth are within the cutting zone at a given time in the following off-line analysis of the responses. This may simplify the task of finding potential correlations between the state of individual teeth on the milling cutter with measured responses from various sensors during the milling process. The proposed method is based on a reflectance detector and uses accurate position information provided by the position encoders.

    A validation of the measurement method is also presented which shows that the error of the estimated angular position is approximately +/- 0.15 degrees for the validation setup used in this case.

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