FUNDAMENTAL ANALYSIS ON THE DYNAMIC BEHAVIOR OF TOOLS WITH STRUCTURED FUNCTIONAL SURFACES IN CUTTING OPERATIONS

Abstract

The productivity of machining processes is often limited by the occurrence of dynamic effects. The investigated approach intends to counteract tool deflections, and thus to damp and disrupt chatter vibrations by using milling tools with defined functional structures on the flank faces at the frontal cutting edges. For the fundamental investigation of the interactions between structural geometric properties and the tool-workpiece interaction, the engagement situation was geometrically evaluated on a highly abstracted level. Subsequently, hypotheses derived from this were validated experimentally in analogy tests with linear cutting motion. In these cutting experiments, dynamic deflections were induced by an external excitation of the specifically compliant modular tool system. Finally, the technologically most relevant structure variants were applied to milling tools and evaluated with regard to their dynamic behavior. This investigation was preceded by a simulation-based analysis of the material removal on the frontal flank face as a function of the process configuration, which is characterized by multiple intersecting cuts in milling processes. By specifically optimizing and coordinating the structure design and the process configuration, an increase in process stability and thus productivity of at least 100% could be achieved.