After reaching to peak force, I am getting another small rise in force signal. What is the possible reason behind it? Machining is performed using orthogonal, down milling process (side milling) with depth of cut 0.3 mm and feed rate of 0.1 mm/rev. The figure presents the one cutting force profile of one cutting cycle.
For people give a opinion, we need more information about the milling process.
When the end mill starts to be in contact with the workpiece, there is an impact force added to the cutting force. Then, the cutting force becomes normal. I guess if you decreased the feed, this force at the beginning would decrease.
Excuse me Sir, but the information is still incomplete.
How many teeths have the mill? What part of this are in simultaneous contact with the part?
Do you know which is the run out of the mill?
Hi Daniel,
milling cutter having an arrangement of using 8 cutting tools, but we are using only one tool as wanted more time gap between two cutting cycles. The diameter of milling cutter is 80 mm. Milling performed on actual and not using any simulation. The operation is side peripheral milling. Please find attached schematic of showing how it is machining.
Excuse me Sagar, the machine is conventional or CNC?
I think that is conventional. May be?
The dynamometer is dynamic (mounted over the spindle), or static (fixed in the table of the milling machine)?
When people cut little depth of cut, increase the possibility to generate vibrations during the machining.
Another possible thing is that the run out of the mill causes the second minor peak force too.
Thanks Daniel, dynamometer is static, fixed on the table. What is exact means run out of the mill?
The run out is the magnitude of excentricity between spindle axis and mill axis. This value can produce noise in the signal.
If the dynamometer was dynamic you can "sense" this noise working in vacuum, without machining.
The possible reason for peaks and valleys in the force signal in intermittent cutting in side milling could be the constant engagement and disengagement of the cutting edge with the workpiece. At higher feed rates and lower cutting speeds the time gap between peak and valley (pitch) is large. At lower feed rates and higher cutting speeds the pitch reduces and peak valleys tend to overlap as next cutting edge of the tool is engaged with the workpiece even before previous cutting edge is disengaged. If you see your force signals the time gap between every peak is about 0.0005 seconds. This gap is time taken by the cutting edge of the tool to engage and disengage with the workpiece.
Regarding the initial high peak from the engagement of cutting edge with the workpiece, it could due to higher initial resistance of the workpiece against edge penetration or may be some ambiguity or error. How about repeating the test multiple times??
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