Fundamental Principles of the Formation of Surface Texture by Disk Mills Used High-Speed Multi-axis Machining

• Published in: Russian engineering research 2023-03, Vol.43 (3), p.364-368
• Main Authors: Pivkin, P. M., Grechishnikov, V. A., Ershov, A. A., Kuznetsov, V. A., Vygzhanin, D. V., Uvarova, L. A.
• Format: Article
• Language: English
• Subjects: Configuration management; Engineering; Engineering Design; High speed; Mathematical models; Microtexture; Model accuracy; Predictions; Principles; Process parameters; Surface layers; Surface properties; Surface roughness; Teeth
• ISSN: 1068-798X; 1934-8088
• DOI: 10.3103/S1068798X23040251

Strict quality requirements on internal surfaces are essential in improving machining technologies, tool design, maching configurations, and machining parameters. Since the surface quality depends on numerous factors affecting high-speed multi-axes milling with circular tool supply, we need to establish principles for selecting the texture . If modeling results for the texture are employed, the time required to attain the specified surface roughness may be greatly reduced, and optimal machining conditions may be selected. However, existing models do not yield reliable data in circular tool supply, on account of the specifics of texture formation over much of the primary cutting edge; for traditional end milling, this problem does not arise. Therefore, in the present work, we propose a new analytical model describing the formation of surface microtexture by disk mills in high-speed multi-axes milling, depending on the mill geometry and cutting conditions. In comparison with existing prediction methods, the proposed model quadruples the accuracy in predicting the surface microtexture when the supply is no more than 0.025 mm per tooth; and doubles the accuracy in the range 0.02–0.04 mm/tooth