Aeroacoustic Performance Evaluation of Milling Cutters Based on the Flow Field on the Cutter Surface

Abstract

Many workers all over the world suffer significant hearing loss as well as psychological and physical stress as a result of exposure to high levels of aeroacoustic noise. Dipole sources are the major noise sources in aeroacoustic noise generation in rotating face milling cutters. A noise model based on the Ffowcs Williams-Hawkings Equation is used to predict aeroacoustic noise; the noise predicted was 2.5dB less than the experimental observations. Flow field of cutter surface was numerically simulated by the resolution of the Navier-Stokes equations (CFD) and five zones on cutter surface were founded to be the important noise source. The broadband noise spreads over a broad range of frequencies and contributes significantly to overall noise, but the discrete noise at the rotational frequency is usually higher and more detrimental to the body.