Modeling and Analysis of Aerodynamic Noise in Milling Cutters

[+] Author and Article Information
Karthikeyan Sampath, Richard E. DeVor

Department of Mechanical and Industrial Engineering,  University of Illinois at Urbana-Champaign, Urbana, IL 61801

Shiv G. Kapoor

Department of Mechanical and Industrial Engineering,  University of Illinois at Urbana-Champaign, Urbana, IL 61801sgkapoor@uiuc.edu

J. Manuf. Sci. Eng 129(1), 5-11 (May 10, 2006) (7 pages) doi:10.1115/1.2335861 History: Received July 15, 2004; Revised May 10, 2006

Aerodynamic noise generated in high speed face milling cutters is usually much higher than the noise exposure limit set by OSHA. Experiments were conducted on two different face milling cutters to understand the aerodynamic noise generation in face milling cutters. It is observed that dipole sources of noise are most important in determining the noise generation in rotating face milling cutters. The aerodynamic noise spectrum consists of discrete tones at the rotational frequency and a broad range of higher frequencies, with the broadband spectrum contributing significantly to overall noise. A mathematical model based on the Ffowcs Williams-Hawkings Equation is used to predict (un-weighted) aerodynamic noise. The noise predicted compares well with the experimental observations. The cutter gullet shape was found to be an important factor in determining broadband noise.

Copyright © 2007 by American Society of Mechanical Engineers
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Figure 1

Photographs of the two face milling cutters

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Figure 2

Experimental setup showing the microphone position

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Figure 3

Average sound pressure level versus tip velocities for the two cutters

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Figure 4

Spectrum of Cutter 1 rotating at 13,000rpm

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Figure 5

3D mesh of control domain

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Figure 6

Spectral plot comparison of (a) Cutter 1, (b) Cutter 2

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Figure 7

(a) Plane AA′ slicing Cutter 1 and Cutter 2 at the gullet region, (b) a closer look at the gullet region showing the relative velocity (with respect to the cutter) vectors of the air flow, (c) cross sectional view of a single gullet (in the plane AA′) showing the relative velocity vectors




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