Abstract
Profile end-milling processes are very susceptible to vibrations caused by cutter runout especially when it comes to operations where the cutter diameter is ranging in few millimeters scale. At the same time, the cutting conditions that are chosen for the milling process have a complementary role on the excitation mechanisms that take place in the cutting area between the cutting tool and the workpiece. Consequently, the study of milling processes in the case that a cutter runout exists is of special interest. The subject of this paper is the experimental analysis of the effect of cutter runout on cutter vibration and, by extension, how this affects the chip removal and, thereby, the workpiece topomorphy. Based on cutting force measurements correlated with the workpiece topomorphy under various cutting process parameters, such as the cutting speed, feed rate, and the axial cutting depth, some useful results are extracted. Hence, the effect of vibration phenomena, caused by cutter runout, on the workpiece topomorphy in end milling can be evaluated.
Highlights
Taking into account that the cutting force is proportional to the axial cutting depth, it is confirmed that by working at higher material removal rates (MRR) more intense tool excitation is expected, leading to vibration phenomena capable of affecting the workpiece surface quality
The effect of the tool runout on the cutting force and thereby on the vibration phenomena is clearly depicted in the Fast Fourier Transform (FFT) spectra of the cutting-force components
In profile end-milling processes, the excitation mechanisms that take place in the cutting area between the cutting tool and the workpiece need to be carefully studied in order to ascertain the factors that affect the cutting operation
Summary
It is very important to know, as precisely as possible, the relationship between the vibration behavior of the machine tool-cutting tool-workpiece system and the cutting conditions (cutting speed, feed rate and axial depth of cut) in order to achieve high workpiece surface quality [1,2].This is especially the case when it comes to the use of contemporary computer numerical control (CNC) machine tools in micromachining processes [3], for which it is crucial to define a group of optimal cutting conditions aiming at: ensuring dynamic stability [4,5] of the cutting process without side vibration phenomena [6] with an unfavorable impact both on the workpiece surface quality and the cutting tool life; achieving efficient machine tool performance; Machines 2018, 6, 27; doi:10.3390/machines6030027 www.mdpi.com/journal/machines avoiding rapid development of cutting tool wear; reducing processing time and production costs.Finding an appropriate combination of process parameters has been such a challenging problem that a great deal of research has been devoted to the topic. It is very important to know, as precisely as possible, the relationship between the vibration behavior of the machine tool-cutting tool-workpiece system and the cutting conditions (cutting speed, feed rate and axial depth of cut) in order to achieve high workpiece surface quality [1,2]. This is especially the case when it comes to the use of contemporary computer numerical control (CNC) machine tools in micromachining processes [3], for which it is crucial to define a group of optimal cutting conditions aiming at: . This is even more important when it comes to micromachining [3,8,9]
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