A Model for the Prediction of Surface Flatness in Face Milling

Author:

Gu F.1,Melkote S. N.1,Kapoor S. G.1,DeVor R. E.1

Affiliation:

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

Abstract

This paper presents a new model for the prediction of surface flatness errors in face milling. The model includes the effects of machining conditions, elastic deformation of the cutter-spindle and workpiece-fixture assemblies, static spindle axis tilt and axially inclined tool path. A new method called equivalent flexibility influence coefficient method is used to compute the elastic deflection of the cutter-spindle and workpiece-fixture assembly at the points of cutting force application. Single insert and multi-insert face milling experiments are conducted to evaluate the predictive ability of the surface flatness model. A comparison of the model predictions and measurements shows good agreement. The influence of static spindle axis tilt on the surface flatness error is found to be very significant. It is shown that care needs to be exercised in comparing the model predictions based on elastic deflection of the machining system and spindle axis tilt with the surface flatness error measurements due to the fact that these measurements may be inflated by inclusion of the surface roughness.

Publisher

ASME International

Subject

Industrial and Manufacturing Engineering,Computer Science Applications,Mechanical Engineering,Control and Systems Engineering

Reference18 articles.

1. Altintas, Y., and Budak, E., 1992, “Peripheral Milling of Flexible Structures,” Proc. ASME Symposium on the Physics of Machining Processes, pp. 97–109.

2. Babin, T. S., Sutherland, J. W., and Kapoor, S. G., 1986, “On the Geometry of End Milled Surfaces,” Proceedings of the 14th North American Manufacturing Research Conference, pp. 168–176.

3. Fu H. J. , DeVorR. E., and KapoorS. G., 1984, “A Mechanistic Model for the Prediction of the Force System in Face Milling Operation,” ASME JOURNAL OF ENGINEERING FOR INDUSTRY, Vol. 106, No. 1, pp. 81–88.

4. Gu, F., Kapoor, S. G., DeVor, R. E., Bandyopadhyay, P., 1994, “An Enhanced Cutting Force Model for Face Milling with Variable Cutter Feed Motion and Complex Workpiece Geometry,” Materials Issues in Machining—II/The Physics of Machining Processes—II, D. A. Stephenson and R. Stevenson, Ed., ASME/TMS, pp. 281–301.

5. Gu, F., 1994, “Prediction of Cutting Forces and Surface Errors in Face Milling with Generalized Cutter and Workpiece Geometry,” Ph.D. Thesis, University of Illinois at Urbana-Champaign.

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