Chip Thickness Analysis Based on Tooth Trajectory for Different End Milling Processes

Abstract

Instantaneous chip thickness during three typical end milling processes is analyzed in this paper. The tooth trajectory of a milling cutter is a combination of two motions, one is the rotation of the cutter spindle and the other is the feed motion of the cutter relative to work-piece. For simplification traditional chip thickness models always simplify the tooth trajectory as a circle to get approximate results. In this paper, modeling of true tooth trajectory in linear, arc and profile end milling processes is studied. And mathematical expresses for entry and exit angles of tooth, feed per tooth along cutter contact path are derived for undeformed chip thickness modeling. The instantaneous chip thickness of each process based on circular tooth trajectory model is analyzed as well for comparison. Cutting forces under different chip thickness models are also predicted to study the effect of tooth trajectory on milling process simulation.

Determining the width of a layer cut with saws with multidirectional teeth

“…Paper [12] describes a method of calculating the thickness of the cut layer during end milling using circular interpolation compared to a linear one. Work [13] modeled the trajectory of the end milling tooth for linear, arc, and profile milling and derived dependences on the thickness of the cut layer, the angles of entry and exit of the tool teeth from a workpiece. In the above works, the dependences of determining the parameters of the cut layer were clarified, in accordance with the trajectories of the tools.…”

“…Our review of works [1][2][3][4][5][6][7][8][9][10][11][12][13][14][15][16][17][18][19] has shown that the existing procedures for determining the thickness of the cut apply only to those tools that operate according to a single cutting scheme; in addition, some of them are approximate. Work [20] is the only one that shows determining the thickness of the cut layer by using CAD systems, for tools whose teeth are assembled in groups.…”