Effect of the Relative Position of the Face Milling Tool towards the Workpiece on Machined Surface Roughness and Milling Dynamics

Abstract

In face milling one of the most important parameters of the process quality is the roughness of the machined surface. In many articles, the influence of cutting regimes on the roughness and cutting forces of face milling is considered. However, during flat face milling with the milling width B lower than the cutter’s diameter D, the influence of such an important parameter as the relative position of the face mill towards the workpiece and the milling kinematics (Up or Down milling) on the cutting force components and the roughness of the machined surface has not been sufficiently studied. At the same time, the values of the cutting force components can vary significantly depending on the relative position of the face mill towards the workpiece, and thus have a different effect on the power expended on the milling process. Having studied this influence, it is possible to formulate useful recommendations for a technologist who creates a technological process using face milling operations. It is possible to choose such a relative position of the face mill and workpiece that will provide the smallest value of the surface roughness obtained by face milling. This paper shows the influence of the relative position of the face mill towards the workpiece and milling kinematics on the components of the cutting forces, the acceleration of the machine spindle in the process of face milling (considering the rotation of the mill for a full revolution), and on the surface roughness obtained by face milling. Practical recommendations on the assignment of the relative position of the face mill towards the workpiece and the milling kinematics are given.

Optimization and Analysis of Surface Roughness, Flank Wear and 5 Different Sensorial Data via Tool Condition Monitoring System in Turning of AISI 5140

“…During the machining, many parameters that change with the increase of wear, such as cutting forces, cutting temperatures, vibrations in the tool, the sound, chip and current, can be used as information sources to determine the severity of tool wear. Therefore, factors affecting the machining economy and productivity, such as tool life, chip control, idle time of the machine, waste material, power and time, can be controlled at the desired level, especially the final targets (production of the workpiece at desired tolerances and surface quality) [ 11 , 12 ]. The main problem that should be solved here is to observe the behavior of different cutting variables simultaneously in the complex nature of machining operations.…”

Optimization of cutting conditions using artificial neural networks and the Edgeworth-Pareto method for CNC face-milling operations on high-strength grade-H steel

“…If we calculate the cost of the milling operation and the input cutting power along the Pareto curve from point 1 to point 11 (see Fig. 8) in accordance with formulas (4) and (5), then C appears to decrease from $27.08 to $24.36, and P c increases from 0.0625 kW to 0.5625 kW. The values of these parameters for the optimums are global optimum C = $25.48, P c = 0.359 kW, local optimum C = $24.36, P c = 0.5625 kW.…”

“…[1]. One of the major control parameters in face milling is surface roughness [2][3][4][5][6][7]. Grade-H steel materials have various uses and many industrial applications, such as cold-formed components in the automobile industry, among others, on account of their high tensile strength.…”

Vibration and displacement analysis during turning of hardened steel

“…Research shows that the position of the tool relative to the workpiece has a significant impact on the dynamics of the process. This affects changes in the maximum instantaneous forces and can affect milling vibration values and surface roughness [8]. Tool wear cannot be omitted, because it results in a shortening of the cutting edge radially, increasing cutting forces, increasing temperature in the cutting zone and changes in affecting of parameters to cutting force [2].…”