Plunge milling operations are used to remove excess material rapidly in roughing operations. The cutter is fed in the direction of spindle axis which has the highest structural rigidity. This paper presents time domain modeling of mechanics and dynamics of plunge milling process. The cutter is assumed to be flexible in lateral, axial, and torsional directions. The rigid body feed motion of the cutter and structural vibrations of the tool are combined to evaluate time varying dynamic chip load distribution along the cutting edge. The cutting forces in lateral and axial directions and torque are predicted by considering the feed, radial engagement, tool geometry, spindle speed, and the regeneration of the chip load due to vibrations. The mathematical model is experimentally validated by comparing simulated forces and vibrations against measurements collected from plunge milling tests. The study shows that the lateral forces and vibrations exist only if the inserts are not symmetric, and the primary source of chatter is the torsional–axial vibrations of the plunge mill. The chatter vibrations can be reduced by increasing the torsional stiffness with strengthened flute cavities.

Time domain model of plunge milling operation

The great mass of machining allowance for blisk is removed in the rough milling, so improving the rough machining efficiency for the blisk’s tunnel is the key of realizing high-efficiency machining of blisk. According to the structure characteristic of open blisk’s tunnel, a four-axis plunge slot rough milling with high-efficiency and low machining cost is advanced. First, the plunge slot process for blisk and the generation process of the ruled enveloping surface for the freeform surface of the blisk’s blade are put forward. Then, the generating method of the ruled enveloping surface for the blade’s freeform surface and the tool path generation method of four-axis plunge slot milling for blisk are studied. The rough milling region of open blisk’s tunnel is determined by generating the ruled enveloping surface of blade’s offset surface, and the algorithm of tool path for four-axis plunge milling is given. When using a ruled surface to approach a freeform surface, the problem of getting boundary is solved, and the error from the calculation of tool path is avoided by the algorithm. At last, the experiment shows that comparing to the traditional side slot milling, the cutting force of four-axis plunge milling can be reduced by 60% and even the rough machining efficiency can be increased to more than double.

Research on tool path planning method of four-axis high-efficiency slot plunge milling for open blisk

Plunge milling operations are used to remove excess material rapidly in roughing operations. The cutter is fed in the direction of the spindle axis which has the highest structural rigidity. This paper presents a comprehensive model of plunge milling process by considering rigid body motion of the cutter, and three translational and torsional vibrations of the structure. The time domain simulation model allows prediction of cutting forces, torque, and vibrations while considering tool setting errors and time varying process parameters. The stability law is formulated as a four-dimensional eigenvalue problem, and the stability lobes are predicted directly with analytical solution in frequency domain. Time domain prediction of cutting forces and vibrations, as well as the frequency domain and chatter stability solution are verified with a series of plunge milling experiments.

Dynamics and stability of plunge milling operations

Plunge milling is a machining process already recognised as able to afford significant gains in productivity during the roughing phases, especially in the case of deep workpieces. It is generally used for machining hard materials but more rarely for light alloys, especially for magnesium alloys. This paper deals with the study and the modeling of cutting forces in plunge milling of magnesium-rare earth alloys. In this study, the authors consider the case of a dry plunge milling process applied to two wrought Mg-Zr-Zn-RE alloys and one cast Mg-Zr-Zn-RE alloy, that are representative of magnesium-rare earth alloys in aerospace industry. This paper investigates the influence of cutting parameters and the influence of edge radius on cutting forces. An analytical model is set up so as to satisfactorily predict the cutting forces for these three representative magnesium alloys studied using just three instrumented tests. An experimental validation through different plunge milling tests shows good agreement between the model and the measured values in a wide range of cutting conditions.

Cutting forces and their modelling in plunge milling of magnesium-rare earth alloys

Time domain simulation model is developed to study the dynamics of plunge milling process for system with rigid and flexible workpiece. The model predicts the cutting forces, system vibration as a function of workpiece and tool dynamics, tool setting errors, and tool kinematics and geometry. A horizontal approach is used to compute the chip area to consider the contribution of the main and side edge in the cutting zone and to deal with any geometric shape of the insert. The dynamic chip area is evaluated based on the interaction of the insert main and side cutting edges with the workpiece geometry determined by the pilot hole and surface left by the previous insert. For the case of system with a flexible workpiece, the workpiece dynamics, as well as its variation in the axial direction with respect to hole location, is considered in the simulation. Cutting tests with single and double inserts were carried out to validate the simulation model and predicted stability lobe for both systems with rigid and flexible workpiece and to check the correctness of the cutting coefficient model. Good agreement was found between the measured and the predicted cutting forces and vibration signals and power spectra. This indicates the ability of the model to accurately predict cutting forces, system vibration, and process stability for process planning prior to machining. The results show dominance of workpiece dynamics in the axial direction for systems with flexible workpiece due to its flexibility as compared to the tool axial rigidity. On the other hand, chatter behavior was found to occur due to tool lateral modes for case of rigid workpiece.

Force prediction and stability analysis of plunge milling of systems with rigid and flexible workpiece

This paper describes the development of an analytical model for the cutting forces in multiblade plunge cutting of cylindrical parts. The development uses the relationship between the instantaneous chip area and the local cutting forces at each individual blade to formulate the total resultant forces via kinematic integration along the cutting edges. The model expresses the cutting forces in explicit terms of part material properties, cutter geometry, part geometry, and cutting conditions. Experiments were performed under various cutting conditions to verify the fidelity of the model at different stages of cutter-part engagement. The waveform and amplitude characteristics of the model-predicted forces agree closely with the measurement. The model can facilitate tool geometry design and cutting condition planning in light of the optimisation of cutting forces.

Force Modelling for Cylindrical Plunge Cutting

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Force Modelling for Cylindrical Plunge Cutting