Modeling of cutter displacements during ball end milling of inclined surfaces

Wojciechowski, Szymon; Chwalczuk, Tadeusz; Twardowski, Paweł; Królczyk, Grzegorz M.

doi:10.1016/j.acme.2015.06.008

Cited by 68 publications

(31 citation statements)

References 18 publications

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“…Figures 2c and 2d reveal also that the qualitative influence of the α and fz factors on the accelerations of vibrations is similar to that observed for the cutting forces. This observation is attributed to the proportionality of tool's displacements to the value of force acting on the tool's working part, according to the milling process' dynamic vibration model [19].…”

Section: Resultsmentioning

confidence: 99%

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The application of response surface method to optimization of precision ball end milling

2017

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Abstract. This paper is focused on the multi criteria optimization of precision ball end milling process of hardened 55NiCrMoV6 steel. The proposed method enables the selection of optimal input parameters which affect the minimization of cutting forces and vibrations signals, as well as the maximization of process efficiency. The experiment includes the measurement of forces and vibrations during the milling tests with variable input parameters. Ultimately, the optimization of the ball end milling process with the application of response surface method is carried out.

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Section: Resultsmentioning

confidence: 99%

“…The equal weights of all responses have been selected. The response utility profiles for the responses were formulated in accordance with the recommendations presented in [19], on the basis of the following expressions:…”

Section: Optimization Based On Response Surface Methodsmentioning

confidence: 99%

The application of response surface method to optimization of precision ball end milling

2017

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“…The instantaneous deflections y(t) of the ball end mill (Fig. 3), induced by cutting forces can be calculated on the basis of the differential motion equation [12]:…”

Section: Ball End Mill Dynamic Deflection Modelmentioning

confidence: 99%

“…According to Jun et al [11] and Wojciechowski et al [12], tool's working part instantaneous displacements during precise milling are significantly affected by the tool deflections induced by cutting forces and machinetoolholder-tool system's geometrical errors (e.g. tool run out).…”

Section: Introductionmentioning

confidence: 99%

The study on dynamic properties of monolithic ball end mills with various slenderness

et al. 2017

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Abstract. The reliable determination of modal mass, damping and stiffness coefficient (modal parameters) for the particular machine-toolholder-tool system is essential for the accurate estimation of vibrations, stability and thus the machined surface finish formed during the milling process. Therefore, this paper focuses on the analysis of ball end mill's dynamical properties. The tools investigated during this study are monolithic ball end mills with different slenderness values, made of coated cemented carbide. These kinds of tools are very often applied during the precise milling of curvilinear surfaces. The research program included the impulse test carried out for the investigated tools clamped in the hydraulic toolholder. The obtained modal parameters were further applied in the developed tool's instantaneous deflection model, in order to estimate the tool's working part vibrations during precise milling. The application of the proposed dynamics model involved also the determination of instantaneous cutting forces on the basis of the mechanistic approach. The research revealed that ball end mill's slenderness can be considered as an important milling dynamics and machined surface quality indicator.

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“…However, forced vibrations can have significant effects on the quality of metal cutting operations and if they are in lateral directions, they may cause significant surface marks on the wall of the hole. Interested readers may refer to [6][7][8][9][10] for more details on forced vibrations in metal cutting.…”

Section: Introductionmentioning

confidence: 99%

Time domain simulation of chatter vibrations in indexable drills

Parsian

Magnevall

Eynian

et al. 2016

Int J Adv Manuf Technol

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Regenerative chatter vibrations are common in drilling processes. These unwanted vibrations lead to considerable noise levels, damage the quality of the workpiece, and reduce tool life. The aim of this study is to simulate torsional and axial chatter vibrations as they play important roles in dynamic behavior of indexable insert drills with helical chip flutes. While asymmetric indexable drills are not the focal points in most of previous researches, this paper proposes a simulation routine which is adapted for indexable drills. Based on the theory of regenerative chatter vibration, a model is developed to include the asymmetric geometries and loadings that are inherent in the design of many indexable insert drills. Most indexable insert drills have two inserts located at different radial distances, namely central and peripheral inserts. Since the positions of the central and peripheral inserts are different, the displacement and thereby the change in chip thickness differs between the inserts. Additionally, the inserts have different geometries and cutting conditions, e.g., rake angle, coating, and cutting speed, which result in different cutting forces. This paper presents a time-domain simulation of torsional and axial vibrations by considering the differences in dynamics, cutting conditions, and cutting resistance for the central and peripheral inserts on the drill. The time-domain approach is chosen to be able to include nonlinearities in the model arising from the inserts jumping out of cut, multiple delays, backward motions of edges, and variable time delays in the system. The model is used to simulate cutting forces produced by each insert and responses of the system, in the form of displacements, to these forces. It is shown that displacements induced by dynamic torques are larger than those induced by dynamic axial forces. Finally, the vibration of a measurement point is simulated which is favorably comparable to the measurement results.

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Modeling of cutter displacements during ball end milling of inclined surfaces

Cited by 68 publications

References 18 publications

The application of response surface method to optimization of precision ball end milling

The application of response surface method to optimization of precision ball end milling

The study on dynamic properties of monolithic ball end mills with various slenderness

Time domain simulation of chatter vibrations in indexable drills

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