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Modeling and simulation of milling processes including process damping effects

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Abstract

Especially in high speed milling of aluminum alloys in the aviation industry, chamfered milling tools have proven themselves. Due to the chamfer, an extended contact between the tool and the workpiece at the flank face is evoked, which leads to additional process damping forces opposed to tool vibrations. Hence, the cutting process shows improved stability characteristics. This article presents an approach for the identification and modeling of these process damping effects in transient milling simulations. For this purpose, a simulation- and experiment-based procedure for the identification of required simulation parameters depending on the tool chamfer geometry is introduced and evaluated. Finally, the identified parameters are used for transient simulations of milling processes with extended stability due to the tool chamfer. The suitability of the proposed identification method and simulation model for milling with process damping is finally proved by a comparison between simulations and experiments.

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Acknowledgments

The authors would like to thank the German Research Foundation (DFG) for their financial support of the presented research project (DE 447/80-1).

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Authors and Affiliations

  1. Institute of Production Engineering and Machine Tools (IFW), Leibniz Universität Hannover, An der Universität 2, 30823, Garbsen, Germany

    B. Denkena, W. Bickel & R. Grabowski

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  1. B. Denkena
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  2. W. Bickel
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  3. R. Grabowski
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Correspondence to W. Bickel.

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Denkena, B., Bickel, W. & Grabowski, R. Modeling and simulation of milling processes including process damping effects. Prod. Eng. Res. Devel. 8, 453–459 (2014). https://doi.org/10.1007/s11740-014-0544-0

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  • DOI: https://doi.org/10.1007/s11740-014-0544-0

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