Geometric analysis of the influence of perpendicularity of a spindle axis of the milling machine on the surface quality

Abstract

This paper deals with analyzes of the influence of the perpendicularity of the spindle of the milling machine on the machined surface. This is part of the geometric errors of machine tools and in a direct manner constitutes a defect on the quality of the workpiece. Therefore, the surface roughness is particularly sensitive to the cutting speed, the feed rate, round of teeth default, the tool tip radius and the cutter teeth number. This article examines the characteristics of the surface topography of steel parts, in finishing machining using milling cutters. The study is conducted by computer simulation tests and experimental part using surface condition monitoring instruments, taking into consideration the round teeth default. The variation of the inclination of the spindle of the milling machine in three positions (90°+ 30#, 90°, and 90°-30#) shows a good agreement between the simulation and the experimental results for sharp and moderately worn tools. Similarly, this study showed that the presented model could thus be integrated into systems computer-aided design and computer-aided manufacturing. Finally, the physical and statistical parameters of roughness during milling at position 90°confirmed that, when the defect of the perpendicularity is eliminated to the maximum, the best surface conditions are obtained.

Performance of wiper geometry carbide tools in face milling of AISI 1045 steel

“…This result indicates that the correct placement of the tool inserts on the cutter is a very important task. Its result heavily influences tool life, agreeing with what was affirmed by Bloul et al [1]. Figure 9 shows the evolution of roughness Ra in relation to the volume of material removed.…”

“…As it is an industrial production process, major investments are needed and the cost reduction plays an important role. In this context, due to the versatility and capability to produce various surfaces, the milling process stands as one of the most used in the metalworking industry [1,2]. Aspects such as high material removal rate, variety of tool geometries, high precision, speed of execution combined with a low cost, allow the milling process to be used in the manufacture of many kinds of geometries, opening possibilities for obtaining high-quality products [3].…”

“…The selection of appropriate machining parameters is an important step in the process planning of any machining operation [2]. In milling operations, the surface roughness is affected by a number of different factors related to the cutting tool, such as stability, protrusion of the cutting edges, cutting geometry, tool wear, cutting conditions, aspects of machines such as machining environment, cutting fluid application, machine conditions, power and rigidity of the machine tool structure of the workpiece material, quality, design, tightening, pre-machining process and other factors [1,2,9,11].…”

“…In milling operations, another factor that has great influence on surface roughness is the tool errors, in particular, the discrepancies in the location of the different cutting tool inserts and the inclination of the milling axis in relation to the feed direction of the cutting process [1,9]. The effect of the undeformed chip thickness on the surface roughness should also be considered, since this parameter plays an important role in chip formation and, therefore, has a strong influence on the imperfections of the machined surface [6].…”

Tribological Behavior and Analysis on Surface Roughness of CNC Milled Dual Heat Treated Al6061 Composites

“…e geometrical parameters of the tool and its radius and the misalignments of the teeth have taken part for improving the machining surface quality as has been discussed. In particular, the better profile of tool selection is an important outcome observed here by Benattia Bloul et al [13]. Paper [14] has discussed the laser metal deposition method of additive manufacturing in milling surface in top and side of the Ti-6Al-4V specimen.…”