Optimisation of face-milling cutters by use of a computeraided milling-system simulator (Camss)

Abstract

This paper focuses on the improvement of the cutting process in milling operations by the reduction of vibrations. For that purpose, a non-uniform chiploading pattern is considered as the design parameter, which is achieved by controlling individual insert geometry, namely axial rake and radial rake angles. In the development of the system model, a complete governing equation that describes the milling process is derived and formulated. The model can represent the closed-loop configuration that consists of the cutting process, structural dynamics and a feedback loop. Based on this model, a computer-aided milling-system simulator (CAMSS) is developed. It takes into account the forced-vibration criterion as well as the self-excited vibration to optimise the cutter geometry. Therefore, it should be able to investigate the effects of cutter geometry on chip loading and vibration. A series of comparisons showed that the optimal cutter was subject to fewer vibrations and lower cutting forces than the conventional one.