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A general on-machine non-contact calibration method for milling cutter runout

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Abstract

Cutter runout is a very common phenomenon in the actual milling process. It always becomes an interference factor, which will cause the distortion of milling force waveform, the variation of milling stability pattern, and the deterioration of machined surface roughness. The paper presents a general on-machine non-contact calibration method for cutter runout, and systematically expounds its causes, types, and identification method. Firstly, a general geometric parameter representation model for the integral and inserted milling cutters is established. Then, three kinds of runout status, including the cutter rotation axis eccentricity, geometric axis eccentricity, and bottom edge eccentricity, are quantitatively described by seven independent parameters. Moreover, by using the eddy current sensor to non-contact measure the target length of the tooth with cutter running on the spindle, the changes of the actual cutting radius at different axial heights on different teeth are obtained. Combined with the numerical optimization method, the separated calibration of the above three types of cutter runout parameters are realized. Finally, a series of verification experiments are carried out for the integral and inserted milling cutters. Both the analysis results of the machined surface morphology and the comparison with the indirect measurement method show that the proposed method is accurate for calibrating the runout parameters. As an on-machine non-contact calibration method, it has a good applicability when dealing with different kinds of cutter, types of runout, and spindle speeds.

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Availability of data and materials

The datasets generated and supporting the findings of this article are obtainable from the corresponding author upon reasonable request. The authors attest that all data for this study are included in the paper.

Abbreviations

XcYcZc :

Cutter geometric coordinate system

XrYrZr :

Cutter rotation coordinate system

XmYmZm :

Machine tool coordinate system

P :

Cutting point on the helix line

Q :

Cutting point on the blade edge

\(z\) :

Axial height of cutting point P

\(r{(}z{)}\) :

Radial distance of cutting point P

\(\psi_{p} (z)\) :

Lag angle of cutting point P

\({\mathbf{Rot}}_{{p{\mathrm{c}}}}\) :

Rotation matrix of the tooth attitude.

i :

Tooth number

l :

Blade number

j :

Cutting unit number

\(\psi_{i,l} (z)\) :

Lag angle of cutting point Q

\(\chi_{i,i + 1,l} (z)\) :

Spacing angle of cutting point Q

\(\phi_{i,l} (z,t)\) :

Rotation angle of cutting point Q

\(R_{i,l,j} (t)\) :

Actual cutting radius of cutting point Q

\(\delta\) :

Cutter rotation axis inclination value

\(\beta\) :

Cutter rotation axis inclination angle

\(\rho\) :

Cutter geometric axis offset value

\(\lambda\) :

Cutter geometric axis offset angle

\(\gamma\) :

Cutter geometric axis inclination value

\(\eta\) :

Cutter geometric axis inclination angle

\(\Delta z\) :

Bottom edge eccentricity value

\(L_{oh}\) :

The tool overhang length.

\(L_{z}\) :

The axis deflection length,

\(L_{i,l,j}^{M}\) :

The measured target length

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Funding

This work was financially supported by the National Natural Science Foundation of China (No. 51905410, 52075426), the Major Science and Technology Project of Shaanxi Province (No. 2019zdzx01-01–02), the China Postdoctoral Science Foundation (No. BX20180253, 219945), and the Fundamental Research Funds for the Central Universities (No. xzy012019009, xxj022019025).

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Authors and Affiliations

  1. State Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong University, Shaanxi Province, Xi’an, 710054, China

    Xing Zhang, Xiaoqian Wang, Zhao Zhao, Kunhong Chen, Jia Yin & Wanhua Zhao

  2. Xi’an Aircraft Industry (Group) Company, Shaanxi Province, Xi’an, 710049, China

    Jia Yin

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  1. Xing Zhang
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  2. Xiaoqian Wang
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  3. Zhao Zhao
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  4. Kunhong Chen
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  5. Jia Yin
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  6. Wanhua Zhao
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Contributions

Xing Zhang does the methodology research, conceptualization, experimental test, formal analysis, and write original draft. Xiaoqian Wang does the milling experiment and data analysis. Zhao Zhao does the experiment and manuscript writing. Kunhong Chen does experimental data collection. Jia Yin does the review and editing. Wanhua Zhao does the methodology research, and feasibility discussion.

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Correspondence to Xing Zhang.

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Zhang, X., Wang, X., Zhao, Z. et al. A general on-machine non-contact calibration method for milling cutter runout. Int J Adv Manuf Technol 120, 7341–7361 (2022). https://doi.org/10.1007/s00170-022-09087-2

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