Mechanistic Modeling of Process Damping in Peripheral Milling

[+] Author and Article Information
C. Y. Huang

Department of Mechanical Engineering,  National Cheng Kung University, Tainan, Taiwan 701

J. J. Junz Wang1

Department of Mechanical Engineering,  National Cheng Kung University, Tainan, Taiwan 701jjwang@mail.ncku.edu.tw


Author to whom correspondence should be addressed.

J. Manuf. Sci. Eng 129(1), 12-20 (Mar 22, 2006) (9 pages) doi:10.1115/1.2335857 History: Received September 07, 2005; Revised March 22, 2006

This paper extends analytical modeling of the milling process to include process damping effects. Two cutting mechanisms (shearing and plowing mechanisms) and two process damping effects (directional and magnitude effects) are included. The directional effect is related to vibration energy dissipation due to directional variation of cutter∕workpiece relative motion. The magnitude effect is associated with change in force magnitude due to variation of rake angle and clearance angle. Process damping is summarized as containing these separate components: direction-shearing, direction-plowing, magnitude-shearing, and magnitude-plowing. The total force model including the process damping effect is obtained through convolution integration of the local forces. The analytical nature of this model makes it possible to determine two unknown dynamic cutting factors from measured vibration signal during milling. The effects of cutting conditions (cutting speed, feed, axial and radial depths of cut) on process damping are systematically examined. It is shown that total process damping increases with increasing feed, axial and radial depths of cut, but decreases with increasing cutting velocity. Predictions based on the analytical model are verified by experiment. Results show that plowing mechanism contributes more to the total damping effect than the shearing mechanism, and magnitude-plowing effect has by far the greatest influence on total damping.

Copyright © 2007 by American Society of Mechanical Engineers
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Figure 1

Force components and cutting geometry in (a) static cutting and (b) dynamic cutting conditions

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Figure 2

Cutting geometry and coordinate systems in the dynamic peripheral milling process: (a) top view; (b) front view

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Figure 3

Process damping functions for each of the four damping mechanisms:(a) direction-shearing; (b) direction-plowing; (c) magnitude-shearing; (d) magnitude-plowing

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Figure 4

Effect of axial depth of cut on process damping functions in Y direction in slot milling with da=3mm: —; da=2mm: -∙-; da=1mm: –––

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Figure 5

Effect of radial depth of cut on process damping functions in Y direction in down milling with dr=10mm: —; dr=5mm: -∙-; dr=2mm: –––

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Figure 6

Experimental setup for the dynamic milling process

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Figure 7

Displacements in Y direction from (a) experiment, (b) simulation with process damping, and (c) simulation without process damping

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Figure 8

Comparison in magnitude of structural damping and each process damping function

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Figure 9

Displacements in Y direction for case D2 from (a) experiment, (b) simulation with process damping and (c) simulation without process damping



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