AN IMPROVED METHOD FOR CUTTER RUNOUT MODELING IN THE PERIPHERAL MILLING PROCESS

Abstract

Cutter runout is an important problem in milling operations. Runout increases the maximum cutting force, degrades the surface finish, increases cutter wear, and affects the dynamic behavior of the cutting process. Unlike past research that has primarily centered on describing the effects of runout on the cutting forces and surface texture, the focus here is on a systematic modeling and measurement technique for cutter runout in peripheral milling. A three-step methodology for runout estimation is presented. The first step comprises of an enhanced runout model that includes the effects of cutter grind, parallel axis offset, and cutter tilt. The next step is to outline a simple procedure to measure the data to be used in the proposed model, and the final step is a technique for the estimation of the runout parameters from this model and the data collected. This runout estimation model is applied to three different types of carefully selected cutters. A designed set of experiments is performed to verify the adequacy of the proposed model and also to compare these predictions with the results obtained by past runout models.

ACKNOWLEDGMENTS

This research was supported in part by the State of Michigan Research Excellence Fund and the Machine Tool Agile Manufacturing Research Institute (MT–AMRI). The authors thank Dr. K. Moon of Michigan Technological University for the technical suggestions, and Dale Harris and Kannan Narayanan for helping with the experiments.