A Dynamic Model of the Cutting Force System in End Milling Including the Effects of Process Damping
 
 

Kannan Narayanan | MS | 1996

ABSTRACT:

End milling is a widely used material removal process in industry. The changing cutting force system in end milling plays a vital role in determining the process performance by influencing the surface accuracy and surface texture, factors that directly affect the quality of the manufactured product. accuracy prediction of the forces is thus required. This thesis attempts to characterize certain aspects of the milling dynamics and develop a computer based model that determines the cutting forces.

A dynamic model of the cutting force system in end milling is developed. This model includes the effects of process damping, cutter runout, and system deflections. Process damping has been attributed to flank face interference mechanism where the clearance face of the cutting tool 'rubs' or interferes with the wavy machined workpiece surface. The ploughing force generated by the rubbing action is considered to be proportional to the contact volume of the interference.The model was implemented with a computer based simulation program. A method to measure cutter runout has been presented. Model verification is performed through machining experiments on 6061-T6 Aluminium. Comparison of the results reveals close agreement between the model predicted and measured forces. Cutting speed is found to have a profound impact on the process damping as it influences the nature of the wavy work surface. This model represents an improvement on the existing models of the end milling process.

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