Influence Characteristics of Tool Vibration and Wear on Machined Surface Topography in High-Speed Milling

Abstract

Existing research on machined surface topography, only consider its response to vibration or wear certain factors, both vibration and wear impact on machined surface topography exist ambiguity and uncertainty, it cannot solve the design conflicts of machined surface topography. For this, this paper analyzes blade installation error, tool wear, vibration and deformation to reveal effects of tip space trajectory, build a three-dimensional model of machined surface topography in simulation, extract its characteristic parameters, by simulation of different amplitudes and wear, found that axis amplitude is a key factor affecting surface residual height, flank wear affects contour distribution distance significantly, by specimen milling experiments, use vibration measuring instrument and ultra-depth microscopy to obtain vibration, wear characteristics and machined surface topography parameters under different cutting parameters, then use the gray system theory to get correlation analysis of the test data, results showed that the influence of tool wear on machined surface topography is prominent than tool vibration.

Analysis and prediction of surface topography characteristics and influence factors of tool passive vibration in milling process

“…By studying the surface topography under different amplitudes, they found that the axial vibration of the tool had the most significant influence on the residual height. Radial amplitude increases the profile distribution distance and Angle, reduces side wear, and increases the profile curvature radius, profile distribution distance and Angle, revealing the coupling effects of vibration and wear on the machined surface topography [1] . Ma et al studied the change rule of the number of cutting edges on milling force and instantaneous deformation in the process of milling thin-panel parts through ABAQUS, and found that multi-tooth milling can obtain better machining quality [2] .…”

“…A parameter system for machining surface topography has been established, which is divided into two directions: u and v, where l u and l v are the contour distances, θ u and θ v is the contour angle. The radial amplitude increases the distance and angle of the contour distribution, reduces lateral wear, and increases the radius of curvature, the spacing and angle of the contour distribution, revealing the coupling effect of vibration and wear on the machined surface topography [1]. Ma et al studied the change rule of the number of cutting edges on milling force and instantaneous deformation in the process of milling thinpanel parts through ABAQUS, and found that multitooth milling can obtain better machining quality [2].…”

The experimental study on interaction of vibration and dynamic force in precision milling process

“…To further determine the influence of spindle vibration on the machining surface, Ma et al [7] investigated the effect of the geometric feature of a curved surface and the cutting direction along the tool path on the variation of force and vibration in high-speed milling. Jiang et al [8] built a three-dimensional model of machined surface topography in simulation to analyze the influence of tool wear and vibration on the spatial trajectory of the knife tip. They concluded that axis amplitude is a key factor affecting surface residual height.…”