Abstract
The article analyzes cutting force oscillations of high-productivity milling. Based on end-milling experiments using a milling machine tool, characteristics of spatial oscillations of cutting forces were identified. The data analysis using software and oscillation theory methods showed that at high spindle rotation frequencies under certain milling conditions, interaction of the cutting edges and the workpiece is not uniform which deteriorates the machined surface. As the spindle rotation frequency increases due to resonances in the tool and spindle and mutual oscillations of the workpiece and the tool, the cutting force spectrum varies. Some extra harmonic components appear. They index the failure of interaction of the cutting edges and the workpiece.
Highlights
Milling as a technological process is characterized by discontinuous force impacts of the mill on the workpiece [1, 2]
Cutting forces were measured with Kistler 9253B23 which can measure three special force components F x, F y, F z (Fig.1)
For measurements 1 and 2, the amplitudes of spectral components at a gear mesh frequency f z exceed the amplitude of spectral peaks at rotational frequency f 1
Summary
Milling as a technological process is characterized by discontinuous force impacts of the mill on the workpiece [1, 2] It causes regular cutting force oscillations P(t) with a gear mesh frequency of f z =n 1 ∙z/60=z∙f 1 where n 1 is the angular speed of mill rotation (rpm); z is the number of mill teeth; f 1 is the rotational frequency (Hz). These regular interferences cause forced oscillations of the mill, spindle, tool and workpiece. During the high-productivity milling process, resonances and spatial oscillations of the mechanical structure and machine unit occur They influence the dynamic characteristics of the machine and milling quality [2]. One more negative vibration effect is milling performance degradation due to limited cutting modes
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