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On the tool vibration effects during down-cut peripheral milling process

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Abstract

Improvement in machining efficiency requires better comprehension of multiphysical cutting process phenomenon under real dynamic cutting conditions. Present work suggests a multi-scale interaction of mesoscopic level cutting with macroscopic level machine tool dynamics to optimize cutting process parameters and potentially improve interactive design process. For that, the case of an orthogonal down-cut peripheral milling, for an aeronautic aluminium alloy A2024-T351, has been treated. A finite element based multi-scale dynamic cutting model has been conceived with a commercial finite element based code ABAQUS®/EXPLICIT to predict the chip morphology under dynamic cutting conditions. Later, combines the elasticity of a classical high speed milling spindle system (tool, tool-holder and rotor) with the mesoscopic level chip formation process. A qualitative parametric study with various stiffness and damping coefficient values for high speed milling spindle system shows that, a less rigid un-damped milling system generates higher amplitude tool vibrations during cutting. In this situation, the temperature rises at tool-workpiece interface, enhancing material softening. Present study deals with the consequences of this softening on affecting the chip morphology (evolution of segmented chip morphology), and machined surface integrity. Further, numerical simulation results depict that the higher values of cutting speed and uncut chip thickness are associated with higher values of milling cutter vibration amplitudes.

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Abbreviations

A :

Initial yield stress (MPa)

a p :

Cutting depth (mm)

B :

Hardening modulus (MPa)

C :

Strain rate dependency coefficient

c eq :

Equivalent linear damping of machining system (kg s−1)

c eqr :

Equivalent rotational damping of machining system (kg m2s−1rad−1)

C p :

Specific heat (J kg−1 °C−1)

D :

Overall damage variable

D1. . .D5:

Coefficients of Johnson-Cook material shear failure initiation criterion

D T :

Tool diameter (mm)

E :

Young’s modulus (MPa)

f :

Feed rate (mm/rev)

G f :

Fracture energy (N/m)

h :

Uncut chip thickness (mm)

I z :

Moment of inertia of the assembly (tool, tool-holder and rotor) (kg m2)

k eq :

Equivalent linear stiffness of machining system (N/m)

k eqr :

Equivalent rotational stiffness of machining system (Nm/rad)

L :

Characteristic length (square root of the integration point element area (mm))

m :

Thermal softening coefficient

m eq :

Equivalent moving mass (kg)

n :

Work-hardening exponent

N :

Spindle rotation frequency (rev/min)

p :

Hydrostatic pressure (MPa)

Px (i) :

x coordinate of the ith tooth of the milling tool (i = 1, 2. . . z t )

Py (i) :

y coordinate of the ith tooth of the milling tool (i = 1, 2. . . z t )

R n :

Tool hone edge radius (μm)

T :

Temperature at a given calculation instant (°C)

T m :

Melting temperature (°C)

T n :

Nodal temperature (°C)

T r :

Room temperature (°C)

\({\bar{{u}}}\) :

Equivalent plastic displacement (mm)

\({\bar{{u}}_f }\) :

Equivalent plastic displacement at failure (mm)

Δu :

Relative displacement of spring element (mm)

V f :

Tool feed velocity (mm/min)

V C :

Cutting speed (m/min)

z t :

Total number of tool teeth

\({\bar{{\varepsilon}}}\) :

Equivalent plastic strain

\({\dot{\bar{{\varepsilon}}}}\) :

Plastic strain rate (s−1)

\({\dot{\bar{{\varepsilon}}}_0 }\) :

Reference strain rate (10−3s−1)

\({\bar{{\varepsilon }}_f }\) :

Equivalent plastic strain at failure

\({\Delta \bar{{\varepsilon}}}\) :

Increment of equivalent plastic strain

\({\bar{{\varepsilon}}_{0i}}\) :

Plastic strain at damage initiation

\({\bar{{\sigma}}}\) :

von-Mises plastic equivalent stress (MPa)

σ n :

Normal stress (MPa)

\({p{/}{\bar{{\sigma}}}}\) :

Stress triaxiality

τ f :

Friction shear stress (MPa)

τ y :

Shear stress (MPa)

ω :

Damage initiation criterion

ν :

Poisson’s ratio

α d :

Expansion coefficient (μ mm−1° C−1)

α o :

Flank/ clearance angle (°)

γ o :

Rake/cutting angle (°)

λ :

Thermal conductivity (Wm−1 C−1)

ρ :

Density (kg/m3)

ζ eq :

Equivalent damping ratio of machining system

θ :

Rotational vibration displacement (°)

ω r :

Angular velocity (rad/s)

μ :

Friction coefficient

dof:

Degree of freedom

MDC-model:

Multiscale dynamic cutting model

OP:

Orthogonal plane

Path i :

Curve traced by TT, i = 1 . . . 5

Plot i:

Curve representing the cutting force (i = 1 . . . 5)

Profile i :

Curve representing the cut surface topology (i = 1. . . 5)

rpm:

Revolution per minute

SSC-model:

Steady state cutting model corresponding to a perfectly rigid spindle system

TT:

Tool tip

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Authors and Affiliations

  1. CNRS, INSA-Lyon, LaMCoS, UMR5259, Université de Lyon, 69621, Lyon, France

    Muhammad Asad, Tarek Mabrouki & Jean François Rigal

Authors
  1. Muhammad Asad
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  2. Tarek Mabrouki
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  3. Jean François Rigal
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Correspondence to Tarek Mabrouki.

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Asad, M., Mabrouki, T. & Rigal, J.F. On the tool vibration effects during down-cut peripheral milling process. Int J Interact Des Manuf 4, 215–225 (2010). https://doi.org/10.1007/s12008-010-0102-8

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  • DOI: https://doi.org/10.1007/s12008-010-0102-8

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