Modelling of the Face-Milling Process by Toroidal Cutter

Abstract

When face milling using a toroidal cutter, with a change in the depth of the cut, the entering angle varies as well. An experimental test of the influence of cutting parameters, such as the depth of the cut and the feed per tooth on the cutting force components and surface roughness parameters, was conducted. The experimental test was carried out using a DMU 100 monoBLOCK CNC machine with registration of cutting force components and surface roughness parameters Ra, Rz, and RSm. FEM analysis of the face-milling process was also carried out and compared with the experimental results. The average deviation of the FEM values for cutting force components does not exceed 12%. Experimental models were established for each force component. It was shown that the depth of the cut has the strongest influence on each force component. The feed per tooth has a little impact on the cutting force. The obtained model of the feed force component is the most complex, and the model of the Fa component is only linear. The influence of the ap parameter on the surface roughness parameters is nonlinear and nonmonotonic. In the range of approx. ap = 2 mm, there is a maximum surface roughness.

Measuring Procedures for Evaluating the Surface Roughness of Machined Parts

“…Surface roughness is a geometric property of the surface, and there are no direct methods to measure it. Surface roughness has a decisive influence on the coefficient of friction of contacting surfaces, on adhesion between surfaces, and various other properties and phenomena; it also has direct effects on the material properties of components [25][26][27][28][29][30][31][32] but also has a key role in other areas, where it significantly affects the function of various devices. Terminology according to the standards and used methods of measurement and data processing is processed in Appendix A.…”

The Review of Current and Proposed Methods of Manufacturing Fir Tree Slots of Turbine Aero Engine Discs

“…Cutting speed can reach up to 25–30 m/min with feed rate of 0.015 mm/blade. The advantage of this method is the possibility of machining arc fir tree slots [ 58 , 59 , 60 , 61 , 62 ].…”

“…Cutting speed can reach up to 25-30 m/min with feed rate of 0.015 mm/blade. The advantage of this method is the possibility of machining arc fir tree slots [58][59][60][61][62]. The use of a carbide broach increased the productivity approximately 2.5 time pared to HSS broach.…”

“…Cutting speed can reach up to 25-30 m/mi feed rate of 0.015 mm/blade. The advantage of this method is the possibility of mac arc fir tree slots [58][59][60][61][62]. Jianhua et al noticed that milling in a single machining pass may lead to sub the cutter to very high thermal loads and, as a result, accelerated tool wear (Figu Therefore, dividing the profile of the slot into a few parts and machining the subse sides and bottom of the slot was proposed [63][64][65][66].…”