The influence of flank lands of end mills on machined surface in milling in the context of chatter

Abstract

Reliability and cost-effectiveness are the main requirements for aircraft materials and structure components used in manufacturing of aviation engines. This defines the requirements for them. The majority of components are thin-walled and made of hard-to-machine materials: nickel and titanium alloys, heat-resistant steels. The use of such materials places restrictions on the use of certain cutting modes. During rough milling and semi-finish milling with end-mill cutters chatter occur. The vibrations deteriorate the machined surface of engine parts, tool life decreases and machine units are worn out. Different process technologies and constructive features of tools are used to decrease the intensity of chatter. The use of end mills having lands has yielded mixed results. The influence of land usage on surface condition and decrease of chatter in up-milling and down milling has been studied. The mechanism of influence on machined surface and chatter in up-milling and down milling has been determined. At the experimental stand studies were carried out on its effect on changes in the laws of motion of detail during the cutting process. It has been shown that in up-milling and down milling, a land fl = 0.05 mm wide on the rear surface along the cutting tooth reduces the intensity of chatter has been shown. The results can be used to select the feed direction to reduce the intensity of chatter when milling thin-walled parts with end mills with a land on the rear surface along the cutting edges.