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Optimal cutting parameter specification of newly designed milling tools based on the frequency monitoring

Abstract

The article deals with the specification of the most suitable machining parameters for three newly designed end mills in the term of stability of the deep groove machining, at which the depth of cut is minimally twice higher the diameter of the cutter. Online vibration analysis was selected as a tool for goal achievement. The partial objective of the first phase of experimental research was to set the boundary conditions of vibrodiagnostics at the specification of the behaviour of three commercially produced milling cutters when the results were compared with the surface roughness achieved at the machining with individual cutting parameters. Vibrodiagnostic conditions were subsequently applied in the second phase of the experiment to determine the most suitable machining parameters of newly designed milling cutters. The Pinnacle VMC 650 CNC machining centre with Fanuc control system was used to perform the experiments. The material of cutters was S-grade sintered carbide, and all the designed cutters were PVD coated with the same AlTiN (aluminium titanium nitride) coating. The machined material was 16MnCr5 (1.7131) steel. The surface roughness analysis after machining by newly designed cutters pointed out that they are better as for the surface quality in comparison with the commercially produced end mills. Finally, it was possible to state that the four-tooth cutter 01-FVT with helix angles (β1 = 39° and β2 = 41°) and tooth pitch (τ1 = 83° and τ2 = 97°) seems to be the best tool for milling deep-shaped grooves among all the tested milling cutters.

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Abbreviations

f n :

Feed per revolution (mm/rev)

f z :

Feed per tooth (mm)

v c :

Cutting speed (m/min)

a p :

Depth of cut (mm)

γ :

Rake angle (°)

β :

Helix lead angle (°)

τ :

Pitch angle of teeth (°)

D :

Diameter of milling cutter (mm)

Ra :

Arithmetical average deviation from a mean line (μm)

Rz :

Maximal height of profile irregularities (μm)

PVD:

Physical vapour deposition

FEM:

Finite element method

RMS:

Root mean square

FFT:

Fast Fourier transformation

CNC:

Computer numerical control

CF:

Crest factor

VQMHVD:

Type of a commercially produced milling cutter

HHW:

Type of a commercially produced milling cutter

BlueCut:

Type of a commercially produced milling cutter

01-FVT:

Type of a newly designed milling cutter

02-FVT:

Type of a newly designed milling cutter

03-FVT:

Type of a newly designed milling cutter

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Acknowledgements

The authors would like to warmly thank Dr. George Pantazopoulos for his great help in preparing the article.

Funding

This study was funded by grants APVV-19-0550, KEGA 007TUKE-4/2018, VEGA 1/0812/21 and KEGA 005TUKE-4/2021.

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Correspondence to Katarina Monkova.

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Monka, P.P., Monkova, K., Majstorovic, V.D. et al. Optimal cutting parameter specification of newly designed milling tools based on the frequency monitoring. Int J Adv Manuf Technol 115, 777–794 (2021). https://doi.org/10.1007/s00170-020-06169-x

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Keywords

  • Mill cutter
  • Tool geometry
  • Deep groove
  • Vibrations monitoring
  • Cutting parameters