Prediction of cutting forces and surface errors in face milling with generalized cutter and workpiece geometry
Gu, Fangming
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https://hdl.handle.net/2142/19610
Description
Title
Prediction of cutting forces and surface errors in face milling with generalized cutter and workpiece geometry
Author(s)
Gu, Fangming
Issue Date
1994
Doctoral Committee Chair(s)
Kapoor, Shiv G.
Department of Study
Mechanical Science and Engineering
Discipline
Mechanical Engineering
Degree Granting Institution
University of Illinois at Urbana-Champaign
Degree Name
Ph.D.
Degree Level
Dissertation
Keyword(s)
Engineering, Industrial
Engineering, Mechanical
Language
eng
Abstract
Face milling is a widely used material removal process in the automotive industry for machining the flat surface of components such as an engine block and cylinder head, etc. The surface flatness error of the machined workpiece is a key variable affecting the quality of the part and the productivity of the process.
The main cause of the surface flatness error in face milling is the elastic deflection of the cutter/spindle and workpiece/fixture assemblies due to forces generated during cutting. To predict the surface flatness error in face milling, knowledge of the cutting forces is required. Numerous models for prediction of cutting forces in face milling have been presented in the literature. However, these models are limited in their scope of applicability. In this thesis, an improved mechanistic cutting force model is developed for face milling with generalized cutter/workpiece geometries and cutter feed paths. The model allows a variety of cutter and insert geometries to be used. It is also capable of simulating the cutting forces for 2-D curvilinear cutter feed paths. Systematic procedures/models to define the cutter-insert-workpiece geometries and variable cutter feed paths and to calculate the undeformed chip thickness, chip area and the cutter entry-exit angles are developed. The surface flatness error model developed here is based on the equivalent flexibility influence coefficients approach which uses the cutting force model and the flexibility influence coefficients of the cutter/spindle and workpiece/fixture assemblies. The model accounts for the effects of changes in cutting conditions and machine setup error (spindle tilt).
Experiments have been conducted to study the effects of cutter-insert geometries, cutter feed path on the cutting force, and the effect of cutting conditions on the surface flatness error. The measured cutting forces have been used to calibrate and verify the developed model for prediction of cutting forces. Comparison between the measured and predicted cutting forces and surface flatness errors show good agreement. From this research, it was also shown that the surface flatness error due to the static spindle axis tilt could be significant, and the roughness error of the machined surface could contribute to the total surface flatness error.
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