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Influence of Axial Depth of Cut and Tool Position on Surface Quality and Chatter Appearance in Locally Supported Thin Floor Milling

Thin floor machining is a challenging and demanding issue, due to vibrations that create poor surface quality. Several technologies have been developed to overcome this problem. Ad hoc fixtures for a given part geometry lead to meeting quality tolerances, but since they lack flexibility, they are ex...

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Autores principales: Casuso, Mikel, Rubio-Mateos, Antonio, Veiga, Fernando, Lamikiz, Aitzol
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2022
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8836450/
https://www.ncbi.nlm.nih.gov/pubmed/35160677
http://dx.doi.org/10.3390/ma15030731
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author Casuso, Mikel
Rubio-Mateos, Antonio
Veiga, Fernando
Lamikiz, Aitzol
author_facet Casuso, Mikel
Rubio-Mateos, Antonio
Veiga, Fernando
Lamikiz, Aitzol
author_sort Casuso, Mikel
collection PubMed
description Thin floor machining is a challenging and demanding issue, due to vibrations that create poor surface quality. Several technologies have been developed to overcome this problem. Ad hoc fixtures for a given part geometry lead to meeting quality tolerances, but since they lack flexibility, they are expensive and not suitable for low manufacturing batches. On the contrary, flexible fixtures consisting of vacuum cups adaptable to a diversity of part geometries may not totally avoid vibrations, which greatly limits its use. The present study analyses the feasibility of thin floor milling in terms of vibration and roughness, in the cases where milling is conducted without back support, a usual situation when flexible fixtures are employed, so as to define the conditions for a stable milling in them and thus avoid the use of ad hoc fixtures. For that purpose, the change of modal parameters due to material removal and its influence on chatter appearance have been studied, by means of stability lobe diagrams and Fourier Transform analysis. Additionally, the relationship between surface roughness and chatter frequency, tooth passing frequency, and spindle frequency have been studied. Ploughing effect has also been observed during milling, and the factors that lead to the appearance of this undesirable effect have been analyzed, in order to avoid it. It has been proven that finish milling of thin floors without support in the axial direction of the mill can meet aeronautic tolerances and requirements, providing that proper cutting conditions and machining zones are selected.
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spelling pubmed-88364502022-02-12 Influence of Axial Depth of Cut and Tool Position on Surface Quality and Chatter Appearance in Locally Supported Thin Floor Milling Casuso, Mikel Rubio-Mateos, Antonio Veiga, Fernando Lamikiz, Aitzol Materials (Basel) Article Thin floor machining is a challenging and demanding issue, due to vibrations that create poor surface quality. Several technologies have been developed to overcome this problem. Ad hoc fixtures for a given part geometry lead to meeting quality tolerances, but since they lack flexibility, they are expensive and not suitable for low manufacturing batches. On the contrary, flexible fixtures consisting of vacuum cups adaptable to a diversity of part geometries may not totally avoid vibrations, which greatly limits its use. The present study analyses the feasibility of thin floor milling in terms of vibration and roughness, in the cases where milling is conducted without back support, a usual situation when flexible fixtures are employed, so as to define the conditions for a stable milling in them and thus avoid the use of ad hoc fixtures. For that purpose, the change of modal parameters due to material removal and its influence on chatter appearance have been studied, by means of stability lobe diagrams and Fourier Transform analysis. Additionally, the relationship between surface roughness and chatter frequency, tooth passing frequency, and spindle frequency have been studied. Ploughing effect has also been observed during milling, and the factors that lead to the appearance of this undesirable effect have been analyzed, in order to avoid it. It has been proven that finish milling of thin floors without support in the axial direction of the mill can meet aeronautic tolerances and requirements, providing that proper cutting conditions and machining zones are selected. MDPI 2022-01-19 /pmc/articles/PMC8836450/ /pubmed/35160677 http://dx.doi.org/10.3390/ma15030731 Text en © 2022 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Casuso, Mikel
Rubio-Mateos, Antonio
Veiga, Fernando
Lamikiz, Aitzol
Influence of Axial Depth of Cut and Tool Position on Surface Quality and Chatter Appearance in Locally Supported Thin Floor Milling
title Influence of Axial Depth of Cut and Tool Position on Surface Quality and Chatter Appearance in Locally Supported Thin Floor Milling
title_full Influence of Axial Depth of Cut and Tool Position on Surface Quality and Chatter Appearance in Locally Supported Thin Floor Milling
title_fullStr Influence of Axial Depth of Cut and Tool Position on Surface Quality and Chatter Appearance in Locally Supported Thin Floor Milling
title_full_unstemmed Influence of Axial Depth of Cut and Tool Position on Surface Quality and Chatter Appearance in Locally Supported Thin Floor Milling
title_short Influence of Axial Depth of Cut and Tool Position on Surface Quality and Chatter Appearance in Locally Supported Thin Floor Milling
title_sort influence of axial depth of cut and tool position on surface quality and chatter appearance in locally supported thin floor milling
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8836450/
https://www.ncbi.nlm.nih.gov/pubmed/35160677
http://dx.doi.org/10.3390/ma15030731
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