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Research Papers

Mechanics and Dynamics of Multifunctional Tools

[+] Author and Article Information
Min Wan

Professor
School of Mechanical Engineering,
Northwestern Polytechnical University,
Xi'an, Shaanxi 710072, China
e-mail: m.wan@nwpu.edu.cn

Zekai Murat Kilic

Department of Mechanical Engineering,
The University of British Columbia,
2054-6250 Applied Science Lane,
Vancouver, BC V6T 1Z4, Canada

Yusuf Altintas

Professor
Fellow ASME
Department of Mechanical Engineering,
The University of British Columbia,
2054-6250 Applied Science Lane,
Vancouver, BC V6T 1Z4, Canada
e-mail: altintas@mech.ubc.ca

1The author was a Visiting Professor at the University of British Columbia supervised by Dr. Yusuf Altintas.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received January 11, 2014; final manuscript received October 1, 2014; published online December 4, 2014. Assoc. Editor: Y. B. Guo.

J. Manuf. Sci. Eng 137(1), 011019 (Feb 01, 2015) (11 pages) Paper No: MANU-14-1019; doi: 10.1115/1.4028749 History: Received January 11, 2014; Revised October 01, 2014; Online December 04, 2014

The mechanics and dynamics of the combined processes are presented for multifunctional tools, which can drill, bore, and chamfer holes in one operation. The oblique cutting forces on each cutting edge with varying geometry are modeled first, followed by their transformations to tangential, radial, and axial directions of the cutter. The regenerative effect of lateral and torsional/axial vibrations is considered in predicting the dynamic chip thickness with multiple delays due to distribution of cutting edges on the cutter body. The lateral and torsional/axial chatter stability of the complete hole making operation is predicted in semidiscrete time domain. The proposed static cutting force and chatter stability prediction models are experimentally proven for two different multifunctional tools in drilling Aluminum Al7050 and Steel AISI1045.

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References

Figures

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Fig. 1

Geometry, coordinates, and cutting forces of three multifunctional tools. (a) Tool 1—Kennametal drill with multiple inserts (XYZ is the Cartesian coordinate system); (b) tool 2—Sandvik TM880 drill with step and chamfer inserts; (c) cutting forces related to the cutting edge elements j and j1 of insert i; and (d) chip thickness variation contributed by lateral deflections.

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Fig. 2

Inserts' geometries and their locations on the shank bodies. (a) Tool 1—Kennametal drill and (b) tool 2—Sandvik TM880 drill.

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Fig. 3

Calculations of axial rake angles in bottom view. (a) Illustration for insert of Tool 1—Kennametal drill and (b) illustration for inserts of tool 2—Sandvik TM880 drill.

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Fig. 4

Process geometries of the inserts during drilling process at a specified time t. (a) Schematics of inserts 1 and 3 being in cut for tool 1—Kennametal drill and (b) schematics of inserts 1 and 3 being in cut for tool 2—Sandvik TM880 drill.

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Fig. 5

Schematics of delay terms in cross-sectional views. (a) For tool 1—Kennametal drill and (b) for tool 2—Sandvik TM880 drill.

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Fig. 6

Schematic setup for measuring torsional–axial transfer function

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Fig. 7

Distribution of cutting force coefficients along the radius of the cutting tools. (a) Tool 1, Aluminum 7050-T7451, Kue=21.4 [N/mm],Kve=33.2 [N/mm] and (b) tool 2, AISI Steel 1045,. Kue=44.0 [N/mm],Kve=45.8 [N/mm].

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Fig. 8

Comparisons of predicted and measured cutting forces. (a) Tool 1, Aluminum 7050–T7451; (b) tool 1, Aluminum 7050–T7451; (c) tool 1, AISI Steel 1045; (d) tool 1, AISI Steel 1045; (e) tool 2 with bottom inserts only, AISI Steel 1045; and (f) tool 2 with all inserts, AISI Steel 1045. Note that in case (e) only the bottom inserts of tool 2 are in cut. In case (f), both bottom and top inserts of tool 2 are in cut.

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Fig. 9

Comparison of predicted and experimentally measured chatter stability limits for tool 1 and tool 2. Feedrate: 0.1 mm/rev. (a) Torsional–axial stability lobes for tool 1. Material: aluminum 7050–T7451 and (b) lateral stability limits for tool 2. Material: AISI Steel 1045.

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Fig. 10

Measured cutting forces and sound along with the photograph of hole shapes for sample experiments with chatter. (a) Tool 1 at spindle speed 1000 rev/min, radial depth of cut = 17 mm, federate = 0.1 mm/rev. Material: aluminum 7050–T7451 and (b) tool 2 at spindle speed 1200 rev/min, radial depth of cut = 2.86 mm, federate = 0.1 mm/rev. Only top inserts are in cut, Material: AISI Steel 1045.

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