A Mechanistic Dynamic Model of End Milling for Process Controller Simulation

[+] Author and Article Information
F. M. Kolarits

The Torrington Co., Norcross, GA 30093

W. R. DeVries

Department of Mechanical Engineering, Aeronautical Engineering and Mechanics, Rensselaer Polytechnic Institute, Troy, NY 12180-3590

J. Eng. Ind 113(2), 176-183 (May 01, 1991) (8 pages) doi:10.1115/1.2899675 History: Received April 01, 1989; Revised March 01, 1990; Online April 08, 2008


In an effort to maximize the metal removal rate in end milling while avoiding excessive cutter deflection or breakage, both fixed gain and adaptive controllers have been implemented for on-line feedrate manipulation to maintain a constant cutting force. While such controllers have been able to increase the metal cutting efficiency, they have also exhibited performance problems when large changes in the process dynamics occur. To assist in controller design and evaluation through digital simulation, a new dynamic model of the end milling force response to changes in feedrate and/or spindle speed is presented. This model, based on chip formation mechanics, takes explicitly into account the effect of cutter runout and deflection on the chip load, permits variations in the axial and radial depths of cut to be modeled, and provides surface geometry predictions. Model predictions are shown to correspond well with experimental machining data.

Copyright © 1991 by The American Society of Mechanical Engineers
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