Prediction model of peripheral milling surface geometry considering cutting force and vibration
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ORIGINAL ARTICLE
Prediction model of peripheral milling surface geometry considering cutting force and vibration Boling Yan 1 & Lida Zhu 1 & Changfu Liu 1 Received: 28 April 2020 / Accepted: 9 August 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Milling surface quality is an important factor to assess the performance of a product, which is usually affected by cutting parameters. This paper presents a novel model of peripheral milling surface topography considering tool vibration. The model used the idea of discretization by introducing the milling dynamics and ignored the effect of tool wear, tilting, and thermal deformation. The simulation results were verified and showed good consistence with experimental results. Afterwards, parametric analysis was conducted to investigate the impact of process parameters and showed that feed per tooth impacts most on the surface roughness while axial depth of cut has the least impact. The presented method enables researchers to predict the peripheral milling surface before processing. Moreover, the method helps to build the formula of surface roughness to conduct the parameter optimization. Keywords Milling dynamics . Surface topography . Tool vibration . Process parameters . Modal analysis
1 Introduction In the field of advanced manufacturing, machined surface quality is an important indicator of product performance. Milling surface quality suggests the machining accuracy and has impact on the abrasive resistance, surface finish, thermal conductivity, and parts’ service life [1]. The milling surface topography indicates the milling surface quality and is closely related to milling force. Usually, the increasing of cutting parameters leads to the growth of the milling force, which will in turn cause the tool to deform and vibrate, and the milling geometry varies due to the change of process parameters. However, the process parameters must be controlled within a proper range to avoid chatter. According to the regenerative chatter theory, if the cutting force exceeds and extends where the stiffness of milling system is too weak to maintain the stable vibration, chatter will happen. Chatter can destroy the
* Lida Zhu [email protected] 1
School of Mechanical Engineering and Automation, Northeastern University, Shenyang 110819, People’s Republic of China
machined surface and leave chatter marks [2]. This article aims to build the prediction model of peripheral milling surface under chatter-free machining condition, and the model does not include chatter condition. In recent years, many researchers have established the surface geometry model of milling process [3–9]. Omar et.al [4] introduced a model to predict surface topography as well as cutting force including effect of tool runout, tool deflection, system dynamics, and tool tilting. Yang and Liu [5] proposed a prediction model of peripheral milling surface topography considering plastic deformation. After experiment and sensitivity analysis, it is found that the effect of cutting speed can be n
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