The Effect of Tool Flexibility on Back-Cutting in End Milled Surfaces

[+] Author and Article Information
S. N. Melkote

George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332

J. W. Sutherland

Department of Mechanical Engineering and Engineering Mechanics, Michigan Technological University, Houghton, MI 49931

C. King

Information Systems Engineering Center, Sandia National Laboratories, Albuquerque, NM 87185

J. Manuf. Sci. Eng 121(3), 532-537 (Aug 01, 1999) (6 pages) doi:10.1115/1.2832713 History: Received November 01, 1996; Revised April 01, 1998; Online January 17, 2008


End milled surface texture is inhomogeneous and often exhibits complex lay patterns. An important contributing factor to these surface characteristics is the back-cutting effect. This effect causes cutter tooth mark patterns on the surface in the forward and reverse tool feed directions. In this paper, the dependence of back-cutting on end mill flexibility and its influence on the slot floor surface texture are modeled and experimentally verified. It is shown that the extent to which tool flexibility affects back-cutting is determined by the resultant cutting force system and not the feed force alone. The variation in the amount of back-cutting typically observed across the width of a milled slot is also explained by this model. The model, although simple in form, yields reasonably good agreement with the measured surface profiles.

Copyright © 1999 by The American Society of Mechanical Engineers
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