Prediction of chatter in NC machining based on a dynamic cutting force model for ball end milling
- 作者：Seon-Jae Kim ; Han Ul Lee ; Dong-Woo Cho
- 关键词：Chatter ; Ball end milling ; Dynamic cutting force model ; Uncut chip thickness model ; NC machining
- 刊名：International Journal of Machine Tools and Manufacture
- 出版年：2007
- 期刊代码：84_08906955
- 类别：et
- 出版时间：October 2007
- 卷：47
- 期：12-13
- 页码：1827-1838
- 文件大小：957 K
摘要
Ball end milling is one of the most widely used cutting processes in the automotive, aerospace, die/mold, and machine parts industries, and the chatter generated under unsuitable cutting conditions is an extremely serious problem as it causes excessive tool wear, noise, tool breakage, and deterioration of the surface quality. Due to the critical nature of detecting and preventing chatter, we propose a dynamic cutting force model for ball end milling that can precisely predict the cutting force for both stable and unstable cutting states because our uncut chip thickness model considers the back-side cutting effect in unstable cutting states. Furthermore, the dynamic cutting force model considers both tool runout and the penetration effect to improve the accuracy of its predictions. We developed software for calculating the cutting configuration and predicting the dynamic cutting force in general NC machining as well as single-path cutting. The chatter in ball end milling can be detected from the calculated cutting forces and their frequency spectra. A comparison of the predicted and measured cutting forces demonstrated that the proposed method provides accurate results.