Skip to main content
SpringerLink
Log in

Failure analysis of support during profile cutting process using horizontal milling machine

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

In this study, the effects of cutting forces on the support of horizontal woodworking milling machine are examined during profile cutting process using both experimental and analytical approaches. The support modeled in 3D using SolidWorks software is a crucial component of the horizontal milling machine used to locate and fix the wood workpiece during the cutting process on the workbench. The effects of cutting forces on the support specimens are measured experimentally considering vibration and failure analyses. Analytical stresses and modal analyses of the support were also calculated using finite element-based analysis approach. Chatter vibration forces of the cutting tool which resulted from cutting forces in x-, y-, and z-directions were calculated analytically during the profile cutting process. The results showed that both cutting and chatter forces are highly effective on the support component failure of the woodworking milling machines.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Bošnjak S, Zrnić N, Simonović A, Momčilović D (2009) Failure analysis of the end eye connection of the bucket wheel excavator portal tie-rod support. Eng Fail Anal 16(3):740–750

    Article  Google Scholar 

  2. Momčilović D, Odanović Z, Mitrović R, Atanasovska I, Vuherer T (2012) Failure analysis of hydraulic turbine shaft. Eng Fail Anal 20:54–66

    Article  Google Scholar 

  3. Bayrakceken H, Ucun I, Tasgetiren S (2006) Fracture analysis of a camshaft made from nodular cast iron. Eng Fail Anal 13(8):1240–1245

    Article  Google Scholar 

  4. İlhan R, Burdurlu E, Baykan İ (1990) Cutting theory in woodworking and furniture industry machines, 3rd edn. Our Office Publications, Ankara, pp 50–61

  5. Landers RG, Ulsoy AG (1996) Chatter analysis of machining systems with nonlinear force processes. In: ASME International Mechanical Engineering Congress and Exposition. pp 183–190

  6. Altintaş Y, Budak E (1995) Analytical prediction of stability lobes in milling. CIRP Ann Manuf Technol 44(1):357–362

    Article  Google Scholar 

  7. Altintas Y (2000) Manufacturing automation: metal cutting mechanics, machine tool vibrations, and CNC design. Cambridge University Press, Cambridge

  8. Hohn RE, Sridhar R, Long GW (1968) A stability algorithm for a special case of the milling process: contribution to machine tool chatter research—6. J Manuf Sci Eng 90(2):325–329

    Google Scholar 

  9. Minis I, Yanushevsky R, Tembo A, Hocken R (1990) Analysis of linear and nonlinear chatter in milling. CIRP Ann Manuf Technol 39(1):459–462

    Article  Google Scholar 

  10. Xiao M, Karube S, Soutome T, Sato K (2002) Analysis of chatter suppression in vibration cutting. Int J Mach Tools Manuf 42(15):1677–1685

    Article  Google Scholar 

  11. Koenigsberger F, Tlustý J (1970) Machine tool structures, vol 1c. Pergamon, New York

  12. Tlusty J, Ismail F (1981) Basic non-linearity in machining chatter. CIRP Ann Manuf Technol 30(1):299–304

    Article  Google Scholar 

  13. Sridhar R, Hohn RE, Long GW (1968) A general formulation of the milling process equation: contribution to machine tool chatter research—5. J Manuf Sci Eng 90(2):317–324

    Google Scholar 

  14. Sridhar R, Hohn RE, Long GW (1968) A stability algorithm for the general milling process: contribution to machine tool chatter research—7. J Manuf Sci Eng 90(2):330–334

    Google Scholar 

  15. Minis I, Yanushevsky T (1993) A new theoretical approach for the prediction of machine tool chatter in milling. ASME J Eng Ind 115:1–8

    Article  Google Scholar 

  16. Budak E (1994) The mechanics and dynamics of milling thin-walled structures. PhD Dissertation, University of British Columbia

  17. Budak E, Altintas Y (1998) Analytical prediction of chatter stability in milling-part I: general formulation. J Dyn Sys Meas Control 120(1):22–30

    Article  Google Scholar 

  18. Budak E, Altintas Y (1998) Analytical prediction of chatter stability in milling-part II: application to common milling systems. J Dyn Sys Meas Control 120(1):31–36

    Article  Google Scholar 

  19. Altintas Y, Shamoto E, Lee P, Budak E (1999) Analytical prediction of stability lobes in ball-end-milling. J Manuf Sci Eng 121(4):586–592

    Article  Google Scholar 

  20. Porankiewicz B, Dolata A, Wieloch G (2008) Wood turning forces. BioResources 3(3):745–757

    Google Scholar 

  21. Bucar B, Kopac J (1996) Dynamic model for the determination of instability of periodic circular cutting of wood tissue. Holz als Roh-und Werkstoff 54:19–25

    Article  Google Scholar 

  22. Bučar B (1997) Influence of the manner of excitation of a machining system on the stability of the process of periodic circular cutting of wood tissue. Holz als Roh-und Werkstoff 55(2–4):121–126

    Google Scholar 

  23. Costes J-P, Ko PL, Ji T, Decès-Petit C, Altintas Y (2004) Orthogonal cutting mechanics of maple: modeling a solid wood-cutting process. J Wood Sci 50(1):28–34. doi:10.1007/s10086-003-0527-9

    Article  Google Scholar 

  24. Bucar B, Bucar DG (2002) The influence of the specific cutting force and cross-sectional geometry of a chip on the cutting force in the process of circular rip-sawing. Holz als Roh-und Werkstoff 60(2):146–151

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Technical Science College, Department of Machine and Metal Technologies, Dumlupinar University, Kutahya, 43100, Turkey

    Kadir Gok

  2. Department of Mechanical Engineering, Dumlupinar University, Tavsanli Yolu 10 Km, Kutahya, 43100, Turkey

    Erol Turkes

  3. Technical Science College, Department of Machine and Metal Technologies, Selcuk University, Konya, 42003, Turkey

    Suleyman Neseli

  4. Department of Mechanical Education, Kocaeli University, Umuttepe Campus, Kocaeli, 41000, Turkey

    Yasin Kisioglu

Authors
  1. Kadir Gok
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Erol Turkes
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Suleyman Neseli
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Yasin Kisioglu
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Kadir Gok.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Gok, K., Turkes, E., Neseli, S. et al. Failure analysis of support during profile cutting process using horizontal milling machine. Int J Adv Manuf Technol 70, 1169–1179 (2014). https://doi.org/10.1007/s00170-013-5356-4

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-013-5356-4

Keywords

Search

Navigation