Optimal cutting condition determination for milling thin-walled
details
Anton Germashev
1
•
Viktor Logominov
1
•
Dmitri Anpilogov
1
•
Yuri Vnukov
1
•
Vladimir Khristal
2
Received: 27 July 2017 / Accepted: 23 April 2018
Ó Shanghai University and Springer-Verlag GmbH Germany, part of Springer Nature 2018
Abstract This paper presents an approach for determining
the optimal cutting condition for milling thin-walled ele-
ments with complex shapes. The approach is based on the
interaction between the thin-walled detail and its periodic
excitation by tooth passing, taking into account the high
intermittency of such a process. The influence of the
excitation frequency on the amplitude of the detail oscil-
lation during milling was determined by simulation and
experiments. It was found that the analytical results agreed
with experimental data. The position of the detail when the
tooth starts to cut was evaluated through experiments. The
influence of this parameter on the processing state is pre-
sented herein. The processing stability is investigated and
compared with the proposed approach. Thereafter, spectral
analyses are conducted to determine the contribution of the
vibrating frequencies to the detail behavior during
processing.
Keywords Thin-walled detail Á High-speed milling Á
Stability Á Surface finish
1 Introduction
End milling is one of the most widely used machining
processes for various thin-walled aerospace and automobile
components. There are specific reasons for its use. The
capability of modern high-speed spindles and accurate
slide systems of machine tools has made this process
competitive with other forms of manufacturing; milling
allows the achievement of excellent dimensional accuracy
and quality of surface finish, as well as producing mono-
lithic parts instead of assembling elements. However, the
productivity of high-speed milling is limited because of the
occurrence of vibrations, called chatter, which leads to
stability loss. It is generally accepted that they are rooted in
a regenerative effect, which appears because of cutting a
previously cut surface. The basic principles of this phe-
nomenon were discovered by Tobias [1], and Koenigs-
berger and Tlusty [2]. Furthermore, Merritt [3] presented
the stability theory, which was later adopted by many
researchers [4, 5]. The theory also served as basis for
constructing what was commonly designated as stability
lobe diagram. Despite the fact that chatter occurs in dif-
ferent metal cutting processes, most approaches have been
conducted based on the turning operation. Tlusty [6], and
Tlusty and Ismail [7] made a detailed analysis of the mil-
ling stability, based on the phenomenon of regenerative
chatter. It must be noted that other reasons for the occur-
rence of vibrations during milling are related to the peri-
odical excitation of the detail by tooth passing, especially
at low axial and radial immersions. Thus, for the prediction
of the milling stability in relation to chatter, the intermit-
tent nature of this process was incorporated [8–13].
Recent developments in milling equipment, which
allowed the production of thin-walled monolithic parts
with complex shapes and surface configurations, have also
changed features of the end milling process. Numerous
operations occur with low radial and axial immersions and
lead to a cutting process where there is not more than one
active tooth (not more than one tooth in the immersion
zone). Moreover, after every consecutive milling process,
& Anton Germashev
germashevanton@mail.ru
1
Mechanical Engineering Department, Zaporizhzhya National
Technical University, Zaporizhzhya 69063, Ukraine
2
Zaporozhye Machine-building Design Bureau Progress State
Enterprise, Zaporizhya, Ukraine
123
Adv. Manuf.
https://doi.org/10.1007/s40436-018-0224-y
@Phil_Robichaud
@deepthiw
@JoseServera