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TECHNICAL PAPERS

An Analytical Design Method for Milling Cutters With Nonconstant Pitch to Increase Stability, Part 2: Application

[+] Author and Article Information
E. Budak

Faculty of Engineering and Natural Sciences, Sabancı University, İstanbul, Turkey

J. Manuf. Sci. Eng 125(1), 35-38 (Mar 04, 2003) (4 pages) doi:10.1115/1.1536656 History: Received September 01, 2000; Revised July 01, 2002; Online March 04, 2003
Copyright © 2003 by ASME
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References

Tlusty, J., and Polacek, 1963, “The Stability of Machine Tools Against Self Excited Vibrations in Machining,” International Research in Production Engineering, ASME, pp. 465–474.
Koenigsberger, F., and Tlusty, J., 1967, Machine Tool Structures-Vol. I: Stability Against Chatter, Pergamon Press.
Tobias, S. A., 1965, Machine Tool Vibration, Blackie and Sons Ltd.
Sridhar,  R., Hohn,  R. E., and Long,  G. W., 1968a, “General Formulation of the Milling Process Equation,” ASME J. Eng. Ind., pp. 317–324.
Sridhar,  R., Hohn,  R. E., and Long,  G. W., 1968b, “A Stability Algorithm for the General Milling Process,” ASME J. Eng. Ind., pp. 330–334.
Minis,  I., and Yanushevsky,  T., 1993, “A New Theoretical Approach for the Prediction of Machine Tool Chatter in Milling,” ASME J. Eng. Ind., 115, pp. 1–8.
Budak,  E., and Altintas,  Y., 1998, “Analytical Prediction of Chatter Stability in Milling-Part I: General Formulation; Part II: Application to Common Milling Systems,” ASME J. Dyn. Syst., Meas., Control, 120, pp. 22–36.
Slavicek, J., 1965, “The Effect of Irregular Tooth Pitch on Stability of Milling,” Proceedings of the 6th MTDR Conference, Pergamon Press, London, pp. 15–22.
Opitz, H., Dregger, E. U., and Roese, H., 1966, “Improvement of the Dynamic Stability of the Milling Process by Irregular Tooth Pitch,” Proceedings of the Adv. MTDR Conference, No. 7, p. 213–227.
Vanherck, P., 1967, “Increasing Milling Machine Productivity by Use of Cutters with Non-Constant Cutting Edge Pitch,” 8th MTDR Conference, Manchester, pp. 947–960.
Tlusty, J., Ismail, F., and Zaton, W., 1983, “Use of Special Milling Cutters Against Chatter,” NAMRC 11, University of Wisconsin, SME, pp. 408–415.
Altintas,  Y., Engin,  S., and Budak,  E., 1999, “Analytical Stability Prediction and Design of Variable Pitch Cutters,” ASME J. Manuf. Sci. Eng., 121, pp. 173–178.
Budak, E., 2003, “An Analytical Design Method For Milling Cutters With Non-Constant Pitch to Increase Stability-Part I: Theory,” ASME J. Manuf. Sci. Eng., Feb.
Budak,  E., and Kops,  L., 2000, “Improving Part Quality in Milling of Titanium Based Impellers by Chatter Suppression and Force Control,” CIRP Ann., 49(1), pp. 31–38.

Figures

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Stability lobe diagram for the end mill with modal parameters shown in Table 1 for slotting magnesium
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Sound spectrums at different rpm’s using regular pitch cutters for the slotting tests in example 1. Note different scales on Y-axis.
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Sound spectrums using the variable pitch end mill in example 1. Note different scales on Y-axis.
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Machining of the compressor and the cutting tool used in example 2
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Sound amplitude and spectrum with the regular cutter in example 2
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Sound amplitude and spectrum with the variable pitch cutter in example 2
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Surface improvement due to variable pitch cutter in example 2
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Sound spectrum for example 3
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Cutting forces with regular and variable pitch cutters in the 5-axis roughing cycle in example 3

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