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

Danil Pimenov,Daniel Suyama,Andres Bustillo,Mozammel Mia,Amauri Hassui,Aristides Magri,Szymon Wojciechowski,Munish Gupta,Grzegorz Krolczyk

doi:10.3390/app9050842

Abstract

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.

Highlights

To manufacture flat surfaces, face milling is widely used as a method of high productivity [1,2,3], and other milling methods [4,5]
The purpose of this study is to investigate the influence of the relative position of the face mill towards the workpiece and milling kinematics on the cutting forces, vibration acceleration, and surface roughness obtained by face milling, and give practical recommendations on the assignment of the relative position of the face mill and workpiece and milling patterns
The variations in cutting force peak values can be induced by the geometrical errors of the machine-toolholder-tool system, which contributes to the changes in real values of axial depths of cut per consecutive tooth

Summary

Introduction

Face milling is widely used as a method of high productivity [1,2,3], and other milling methods [4,5]. At the same time, when describing cutting modes, such as in Guzeev et al [6], usually there are recommendations about the amount of position symmetry of the cutter and workpiece with asymmetric processing circuits as a range e = (0.03–0.06)B, where. Very often cutting tool manufacturing handbooks only contain the processing circuit with position symmetry of the cutter and workpiece, or there is a given displacement range. The work of Diniz and Filho [8] demonstrated that an asymmetric circuit with an offset close to zero provided for the best tool list. The paper of Bağcı and Aykut [9] proved that the cutting force in milling is lower when using an asymmetric scheme as opposed to symmetrical milling. In reference [10], it is shown that the cutting force is pulsating, which is associated with a variable number of the cutter’s teeth involved in the process that will certainly cause vibrations in a real system

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