WCSE

Milling Strategy Design to Improve Vibration Behavior, Tool Wear and Surface Roughness in Machining

Abstract— Uncontrollable vibration behavior during the milling process impairs the surface quality of the workpiece and escalate the machine damage as well as machine and tool wear. In this work, the impact of various milling strategies with control optimization for three different types of milling operations are studied. To objectively quantify the process quality, the machining time, the width of tool wear marks and the surface quality after each experiment as well as the vibration amplitude and the bending moment of the tool holder during the process have been measured and evaluated. For every milling type, three milling strategies with three iterative experiments each have been carried out. As a result, a database with vibration-related data and information for different milling strategies has been established. Thus, the machining process of workpieces with diverse geometric elements and the corresponding manipulated variables can be assessed regarding the vibration and tool wear behavior. Based on the experimental results, the potentials of the vibration-minimized milling strategies and tool path design in enhancing the process stability, the productivity and the tool life can be verified.

Index Terms— milling operations; chatter suppression; process optimization.

Shu Ju
Institute of Resource and Energy Efficient Production Systems, Friedrich-Alexander-Universität Erlangen-Nürnberg, Germany;
Nico Hanenkamp
Institute of Resource and Energy Efficient Production Systems, Friedrich-Alexander-Universität Erlangen-Nürnberg, Germany;

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Cite: Shu Ju, Nico Hanenkamp, " Milling Strategy Design to Improve Vibration Behavior, Tool Wear and Surface Roughness in Machining, " WCSE 2022 Spring Event: 2022 9th International Conference on Industrial Engineering and Applications, pp. 1115-1128, Sanya, China, April 15-18, 2022.