Modeling cutter tilt and cutter-spindle stiffness for machine condition monitoring in face milling using high-definition surface metrology

Nguyen, Hai Trong; Hui, Wang; Hu, S. Jack

doi:10.1007/s00170-013-5347-5

Cited by 25 publications

(10 citation statements)

References 15 publications

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“…The following papers are dedicated to theoretical and experimental studies of face milling processes [48][49][50][51][52][53]. Totis et al [48] investigated measurement of the cutting force in face milling and proposed a novel rotating dynamometer for this purpose.…”

Section: Introductionmentioning

confidence: 99%

“…Rosales et al [49] focused on applying the novel method of dynamic register cutting forces using predictive statistical methods. Nguyen et al [50] presented a novel approach to monitoring the spindle title and deflection with the help of HDM (high-definition metrology) surface data. Pimenov [51] developed a mathematical model for the main drive power expended in face milling, taking into consideration the wear of teeth on the back surface of the tool.…”

Section: Introductionmentioning

confidence: 99%

“…Luan et al [53] structured a predictive model for power in face milling used in the manufacturing processes. However, papers [48][49][50][51][52][53] are not concerned with developing the conditions that ensure the optimum position of the face mill and the workpiece which provides the minimum surface roughness.…”

Section: Introductionmentioning

confidence: 99%

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

et al. 2019

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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.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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

et al. 2019

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“…Consequently, the true variogram shows a more complicated pattern rather than increasing monotonically. Surfaces with such periodicity are common in manufacturing, e.g., tool surfaces in ultrasonic welding [3] and machined surfaces [22][23][24]. For example, the anvil surfaces in ultrasonic metal welding show strong spatial periodicity, as illustrated by Figure 1.1.…”

Section: Table Of Contents Introductionmentioning

confidence: 99%

Spatial Interpolation for Periodic Surfaces in Manufacturing Using a Bessel Additive Variogram Model

Yang

Shao

2018

Journal of Manufacturing Science and Engineering

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High-resolution spatial data are essential for characterizing and monitoring surface quality in manufacturing. However, the measurement of high-resolution spatial data is generally expensive and time-consuming. Interpolation based on spatial models is a typical approach to cost-effectively acquire high-resolution data. Conventional modeling methods fail to adequately model the spatial correlation induced by periodicity, and thus their interpolation precision is limited. In this paper, we propose using a Bessel additive periodic variogram model to capture such spatial correlation. When combined with kriging, a geostatistical interpolation method, accurate interpolation performance can be achieved for common periodic surfaces. In addition, parameters of the proposed model provide valuable insights for the characterization and monitoring of spatial processes in manufacturing. Both simulated and real-world case studies are presented to demonstrate the effectiveness of the proposed method.

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“…Their work emphasized on the optimization of machining parameters to minimize surface deformation under machining loads. Nguyen et al [30] proposed a method to monitor spindle tilt and cutter spindle deflection using surface data measured by high-definition metrology. Cutter spindle deflection was used to correlate the machine conditions such as loose and worn bearing for process diagnosis.…”

Section: Introductionmentioning

confidence: 99%

A study of the influence of processing parameters and tool wear on elastic displacements of the technological system under face milling

Pimenov

Guzeev

Mikołajczyk

et al. 2017

Int J Adv Manuf Technol

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A study of the influence of processing parameters and tool wear on the total elastic displacements of the technological system is based on a mathematical model of elastic displacements during face milling. The mathematical model takes into account both plane-parallel and angular displacements of the subsystems 0-"workpiece-device-machine table" and 1-"tool-device-z-head system." The article covers the method of experimental determination of the element compliances of the GF2171S5 milling machine technological system. Angular compliances of the spindle assembly are not listed in the milling machine technical data sheet; therefore, this work gives a method for compliance determination along the coordinate axes of the machine and angular compliances of subsystems of the technological system. The article presents the adequacy assessment of mathematical models of elastic displacements of the technological system under face milling, for different values of tool flank wear on the flank surface. The article also presents the influences of face milling process parameters (workpiece material, cutting speed, cutting depth, the main cutting-edge angle, the cutter overhang to its diameter ratio, feed per tooth, and different values of the tool flank wear on the flank surface) on the total elastic displacements of the technological system, based on the estimated mathematical model of the elastic displacements of the technological system during face milling.

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Modeling cutter tilt and cutter-spindle stiffness for machine condition monitoring in face milling using high-definition surface metrology

Cited by 25 publications

References 15 publications

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

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

Spatial Interpolation for Periodic Surfaces in Manufacturing Using a Bessel Additive Variogram Model

A study of the influence of processing parameters and tool wear on elastic displacements of the technological system under face milling

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