Cutter Exit Effects during Milling of Thin-Walled Inconel 718

Abstract:

During milling of thin-walled components, chatter vibrations give rise to process issues. These include dimensional inaccuracy, damaged and scrap parts, and damaged cutting tools. This, in turn, leads to loss of production time with increasing cost as a consequence. This paper identifies the force profile during a single cut milling process. It focuses on the exit and post-exit behavior of the cut and discusses the process dynamics. The force profiles of various tool-to-workpiece positions are analyzed as regards the exit and post exit phases. A standard on-the-market cutter and a specially designed zero rake cutter are used in the investigation. Finally, a time-domain simulation of the force is performed and compared to the experimental results. The study concludes that a small change in exit angle may result in a considerable improvement in cutting behavior. In addition, the tool position should be chosen so that the cutter exits in the least flexible direction possible for the workpiece.

• Periodical: Advanced Materials Research (Volume 590)
• Pages: 297-308
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.590.297
• Online since: November 2012
• Authors: B. Wanner, M. Eynian, T. Beno, L. Pejryd
• Keywords: Chatter Vibrations, Exit Angle, Inconel 718, Process Stability, Thin Wall

References

[1] B. Wanner, M. Eynian, T. Beno and L. Pejryd. Millin Strategies for Thin-walled Components, Advanced Materials Research special edition Advances in Materials Processing Technologies,. Vol. 498, pp.177-182, (2012).

DOI: 10.4028/www.scientific.net/amr.498.177

[2] A.J. Pekelharing. The Exit Failure in Interrupted Cutting. Annals of the CIRP, Vol. 27, No. 1, pp.5-10, (1978).

[3] A.J. Pekelharing. The Exit Failure of Cemented Carbide Face Milling Cutters, Part I – Fundamentals and Phenomenae. Annals of the CIRP, Vol. 33, No. 1, pp.47-50, (1984).

DOI: 10.1016/s0007-8506(07)61377-8

[4] A.J. Pekelharing. The Exit Failure of Cemented Carbide Face Milling Cutters, Part II – Testing of Commercial Cutters. Annals of the CIRP, Vol. 33, No. 1, pp.51-54, (1984).

DOI: 10.1016/s0007-8506(07)61378-x

[5] J. Tlusty and F. Ismail. Basic Nonlinearity in Machining Chatter, Annals of the CIRP, 30121-25 (1981).

DOI: 10.1016/s0007-8506(07)60946-9

[6] M.C. Avila and D.A. Dornfeld. On the Face Milling Burr Formation Mechanism and Minimization Strategies at High Tool Engagement. Consortium on Deburring and Edge Finishing, Laboratory for Manufacturing and Sustainability, UC Berkely, (2004).

[7] S. Tripathi and D.A. Dornfeld. Review of Geometric Solutions for Milling Burr Prediction and Minimization. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture April 1, 2006 220: 459-466.

DOI: 10.1243/095440505x32652