TY - JOUR

T1 - Using tool wear to increase process stability when milling Al7075 and AISI 4140+QT

AU - Denkena, Berend

AU - Krödel, Alexander

AU - Relard, Andreas

N1 - Funding Information: The presented investigations were undertaken with support of the German Federation of Industrial Research Associations (AiF) within the project “Potential for increasing productivity through wear-related process damping” (IGF 20636 N/1). The authors would like to thank the AiF for the financial and organizational support of this project and the companies Seco Tools and Gühring KG for providing the milling tools.

PY - 2021/12

Y1 - 2021/12

N2 - One of the main limits of productivity during cutting processes is the occurrence of regenerative chatter. Due to these self-excited vibrations, the load capacity of the machine components, the tool as well as the machine performance cannot be fully utilized. There are several methods to stabilize the milling process. One is the use of increased process damping, which results from the contact of the tool’s flank face and the workpiece. The flank wear land naturally increases the contact between tool and workpiece. However, this effect has not been used to increase productivity in milling processes. This paper investigates with experiments and numerical simulations how tool wear affects process stability in milling of aluminum and steel. Therefore slot milling and side milling tests were carried out with tools of various states of flank wear. It could be shown that increasing flank wear allows to raise the depth of cut ap up to 300% in machining aluminum and perform the machining process with a higher productivity.

AB - One of the main limits of productivity during cutting processes is the occurrence of regenerative chatter. Due to these self-excited vibrations, the load capacity of the machine components, the tool as well as the machine performance cannot be fully utilized. There are several methods to stabilize the milling process. One is the use of increased process damping, which results from the contact of the tool’s flank face and the workpiece. The flank wear land naturally increases the contact between tool and workpiece. However, this effect has not been used to increase productivity in milling processes. This paper investigates with experiments and numerical simulations how tool wear affects process stability in milling of aluminum and steel. Therefore slot milling and side milling tests were carried out with tools of various states of flank wear. It could be shown that increasing flank wear allows to raise the depth of cut ap up to 300% in machining aluminum and perform the machining process with a higher productivity.

KW - Chatter

KW - Milling

KW - Productivity

KW - Stability

KW - Wear

UR - http://www.scopus.com/inward/record.url?scp=85105962416&partnerID=8YFLogxK

U2 - 10.1007/s11740-021-01059-x

DO - 10.1007/s11740-021-01059-x

M3 - Article

AN - SCOPUS:85105962416

VL - 15

SP - 843

EP - 853

JO - Production Engineering

JF - Production Engineering

SN - 0944-6524

IS - 6

ER -