Correlation of vibration and cutting forces in thin-walled machining

Abstract

The lack of stiffness of thin-walled parts results in easy deflection under the cutting forces during the milling process. In this case, it is important to predict the cutting forces of milling thin-walled sections so that the wall sections are maintained at high accuracy. The prediction and analysis of cutting forces could play an essential role to select the cutting conditions, tooling and the system of machining used. Furthermore, the prevention of vibration, chatter, deformation, dimensional error and the maintenance of stable conditions of machining can be obtained by predicting the cutting forces. Many researchers have taken this topic into account and applied the theoretical concepts, simulation and other technical approaches to predict the cutting forces during machining operations so that good machining results can be obtained. In this paper a methodology is developed to correlate the vibrational characteristics of the cutting process with the forces developed by the process. If this correlation exists then it is possible to develop a modelling approach to determine the characteristics of the thin walled sections can be determined. The work that will be described in this paper will present a technique to correlate the data and the use of the data for the development of the modelling approach. The experimental set-up and procedure will be presented and discussed. From this information it will be shown which characteristics can be correlated. Finally the feasibility of the process will be discussed.