The Influence of Tool Orientation on Cutting Forces during End Milling

Ponomarev, Boris; Hien, Nguyen Sy

doi:10.18698/0536-1044-2019-3-11-20

Cited by 8 publications

(2 citation statements)

References 13 publications

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“…Во-первых, чем больше амплитуда виброперемещений, соответствующая частоте резания, тем выше значение амплитудных параметров шероховатости. Во-вторых, амплитуда виброперемещений изменяется при увеличении угла наклона нелинейно, а снижение качества обработанной поверхности происходит ввиду упругих деформаций режущего инструмента, что объясняется распределением составляющих сил резания вдоль режущей кромки [20,23].…”

Section: методика экспериментального исследованияunclassified

Experimental study of the dynamics of the machining process by ball-end mills

Gimadeev¹,

Li²,

Berkun³

et al. 2023

Metal Working and Material Science

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Introduction. Due to a significant number of factors affecting the change in the properties of a dynamic system, excessively conservative processing conditions are chosen to ensure the high quality of the resulting product. This limits the efficiency of the process and leads to an increase in the cost of production. Accordingly, modern approaches are needed that will allow diagnosing the current state of processing and making timely decisions to replace the tool, correct or change the control program. The significance of the ongoing research is to propose a real-time monitoring approach to milling control to identify emerging processing errors, predict potential problems and improve uptime. Subject. The paper discusses the features of the real-time monitoring system during mechanical processing with a single- and double-edge cutting tool, taking into account acoustic wave filtering, minimizing surface roughness. The purpose of the work is to determine the effect of the inclination orientation of the ball-end tool on the surface roughness value using real-time monitoring during milling on CNC process equipment. Methods. The study provides methods of correlation and regression analysis. The calculated data were obtained by means of vibroacoustic diagnostics and measured in the range of values of the variable angle of inclination of the surface for single- and double-edge cutting tool based on the provisions of the theory of oscillations and vibroacoustic diagnostics, cutting theory, digital processing and digital filtering of signals. Results and discussions. Experimental data obtained during machining made it possible to determine that an increase in the angle of inclination of a single-edge cutting tool has practically no effect on the change in the amplitude parameters of roughness. The values of vibroacoustic diagnostics and roughness, when using a double-edge ball-end tool, show a consistent picture with the effects created by the angles of inclination and advance. The obtained solutions to the problems of monitoring and analyzing the roughness parameters can significantly reduce the amount of experimental research and clarify the idea of the practical implementation of the method of acoustic monitoring of the cutting process.

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Section: методика экспериментального исследованияunclassified

Experimental study of the dynamics of the machining process by ball-end mills

Gimadeev¹,

Li²,

Berkun³

et al. 2023

Metal Working and Material Science

View full text Add to dashboard Cite

show abstract

“…Анализ научной литературы позволяет говорить о растущем интересе к теме обеспечения нужных параметров шероховатости за счет обоснованного выбора траекторий формообразующих движений и ориентации сфероцилиндрического инструмента при фрезеровании пространственно-сложных поверхностей (ПСП) [4][5][6][7]. Примеры таких деталей: формообразующие элементы штамповой оснастки, мастер-модели для литья, исполнительные поверхности зубчатых передач [8][9][10].…”

Section: аннотацияunclassified

Influence of the Sphero-Cylindrical Tool Orientation Angles on Roughness under Processing Complex-Profile Surfaces

Gimadeev,

Nikitenko,

Berkun

2023

Vestnik Donskogo gosudarstvennogo tehničeskogo universiteta

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Introduction. When milling complex-profile surfaces of parts, the selection of tool trajectories and orientations affect the roughness parameters. However, in the studies devoted to the formation of trajectories, recommendations to provide the quality of microgeometry of surfaces were not taken into account. Moreover, when writing programs for CNC equipment in CAM systems, the limitations of cutting modes were determined exclusively using a geometric approach. It did not take into account the influence of the orientation angles of the sphero-cylindrical tool relative to the normal plane on the quality of surface treatment, namely on roughness. The work was aimed at the creation of the methodology for selecting the limiting values of the orientation angles of a sphero-cylindrical tool to optimize the process of machining spatially complex surfaces. The tasks included achieving the minimum values of the amplitude roughness parameter Rz and determining the effectiveness of various machining paths.Materials and Methods. Methods of correlation and regression analysis were used, the results were compared and generalized. The least-squares method was applied to estimate the parameters of the regression equation. The DMU 50 ecoline processing center was used for the experimental studies. Roughness was measured on a Surfcam 1800 D profilometer. The material of the samples was steel 12X18N10T. The material of the tool was hard alloy 1620 Sandvik with PVD coating (physical vapor deposition, the closest domestic analogue is T15K6).Results. It has been shown in detail how roughness parameters Rz depend on the angle of inclination and the diameter of the tool. Twenty examples were summarized in a table. Natural regression coefficients were calculated using linear and hyperbolic models. It was found that the diameter of the tool had a greater effect on the formation of roughness parameter Rz than the angle of inclination. For a detailed description of the influence features, the coefficients of multiple, partial, paired correlation and multiple determination were compared. The limitations associated with the angles of inclination of the tool when processing complex surfaces were determined. A scheme for calculating the angle of the normal was visualized, which included the selected step along the axis to determine the lengths of the segments of the broken curve. The profilograms of surfaces obtained with different shaping trajectories were given in the form of drawings. This allowed us to conclude that milling from top to bottom is unsuitable when the tool is tilted 5°– 35°. A map has been compiled by which it is possible to judge the roughness, knowing the type of milling and the inclination angle (from 5° to 80 °). The dependence of the roughness parameter on the processing speed and the use of coolant was represented graphically. The calculated parameters for determining the optimal angle of inclination of the tool were tabulated. Their analysis proved the adequacy of the proposed method of preparing control information.Discussion and Conclusion. The presented technique made it possible to determine the optimal values of the orientation angles of the sphero-cylindrical tool, taking into account the cutting speed and the minimum possible amplitude roughness parameter Rz. The pattern of feeding fz = 0.4 mm/tooth for surface areas with a total angle of 5°– 50°was considered. In this case, processing along trajectories in the passing, opposite and bottom-top directions, provided roughness in the range of 3–6 µm according to parameter Rz. The top-down toolpath is not recommended for use in final operations due to the significant height of parameter Rz.

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