Author： Bachrathy D. Insperger T. Stepan G.
Publisher： Taylor & Francis Ltd
ISSN： 1091-0344
Source： Machining Science and Technology, Vol.13, Iss.2, 2009-04, pp. : 227-245
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Abstract
Stability and surface errors are investigated numerically for milling operations with a helical tool. A detailed two degree of freedom mechanical model is derived that includes both surface regeneration and the helical teeth of the tool. The governing delay-differential equation is analyzed by the semi-discretization method. The surface errors are predicted based on the (stable) forced motion of the tool. New surface error parameters were introduced to characterize the properties of the spatial machined surface. The errors were calculated numerically for a given machine tool and workpiece for different axial depths of cut and spindle speeds. It is shown that both good surface properties and large material removal rate can be achieved by appropriate axial immersion in case of helical fluted tool. This phenomenon was proved analytically by means of the Fourier transformation of the cutting force.
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