Precision surface characterization for finish cylindrical milling with dynamic tool displacements model |
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| Affiliation: | 1. Faculty of Mechanical Engineering and Management, Poznan University of Technology, 3 Piotrowo St., 60-965 Poznan, Poland;2. Faculty of Mechanical Engineering, University of Zielona Gora, 4 Prof. Z. Szafrana Street, 65-516 Zielona Gora, Poland,;3. Turbocharger Research Institute, University of Huddersfield, Huddersfield HD1 3DH, UK,;4. Faculty of Mechanical Engineering, Opole University of Technology, 76 Proszkowska St., 45-758 Opole, Poland;1. Department of Automated Mechanical Engineering, South Ural State University, Lenin Prosp. 76, Chelyabinsk, 454080, Russia;2. Faculty of Mechanical Engineering, Opole University of Technology, 76 Proszkowska St., Opole, Poland;3. Mechanical and Production Engineering, Ahsanullah University of Science and Technology, Dhaka, 1208, Bangladesh;4. Faculty of Mechanical Engineering and Management, Poznan University of Technology, 3 Piotrowo St., 60-965, Poznan, Poland;1. Department of Mechanical Engineering, National University of Singapore, 9 Engineering Drive 1, Singapore 117576, Singapore;2. Singapore Institute of Manufacturing Technology, 71 Nanyang Drive, Singapore 638075, Singapore;1. Universidad de Navarra, TECNUN Escuela de Ingenieros, Paseo Manuel de Lardizábal 15, San Sebastián, 20018, Spain;2. Universidad Politécnica de Cartagena, C/ Doctor Fleming s/n, Cartagena, 30202, Spain;1. University of Strathclyde, Department of Mechanical and Aerospace Engineering, Glasgow, UK;2. University of Bath, Department of Mechanical Engineering, Bath, UK |
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| Abstract: | In this work a new approach to surface roughness parameters estimation during finish cylindrical end milling is presented. The proposed model includes the influence of cutting parameters, the tool’s static run out and dynamic phenomena related to instantaneous tool deflections. The modeling procedure consists of two parts. In the first stage, tool working part instantaneous displacements are estimated using an analytical model which considers tool dynamic deflections and static errors of the machine – tool-holder – tool system. The obtained height of the tool’s displacement envelope is then applied in the second stage to the calculation of surface roughness parameters. These calculations assume that in the cylindrical milling process, two different mechanisms of surface profile formation exist. Which mechanism is present is dependent on the feed per tooth and the maximum height of the tool’s displacement envelope. The developed model is validated during cylindrical milling of hardened hot-work tool steel 55NiCrMoV6 using a stylus profiler and scanning laser vibrometer over a range of cutting parameters. The surface roughness values predicted by the developed model are in good agreement with measured values. It is found that the employment of a model which includes only the effect of static displacements gives an inferior estimation of surface roughness compared to the model incorporating dynamic tool deflections. |
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| Keywords: | Finish milling Tool displacement Run out Surface roughness Laser vibrometry |
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