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Appl. Sci. 2019, 9(5), 842; https://doi.org/10.3390/app9050842

Effect of the Relative Position of the Face Milling Tool towards the Workpiece on Machined Surface Roughness and Milling Dynamics

1
Department of Automated Mechanical Engineering, South Ural State University, 454080 Chelyabinsk, Russia
2
Department of Manufacturing and Materials Engineering, School of Mechanical Engineering, University of Campinas, Campinas 13083-860, Brazil
3
Faculty of Mechanical Engineering and Management, Poznan University of Technology, 60-965 Poznan, Poland
4
Mechanical and Production Engineering, Ahsanullah University of Science and Technology, Dhaka 1208, Bangladesh
5
Faculty of Applied Sciences, University of Campinas, Rua Pedro Zaccaria, Limeira 13484-350, Brazil
6
Department of Civil Engineering, University of Burgos, 09006 Burgos, Spain
7
Faculty of Mechanical Engineering, Opole University of Technology, 76 Proszkowska St., 45-758 Opole, Poland
8
University Center For Research and Development, Chandigarh University, Gharuan, Mohali-140413, Punjab, India
*
Author to whom correspondence should be addressed.
Received: 10 February 2019 / Revised: 20 February 2019 / Accepted: 21 February 2019 / Published: 27 February 2019
(This article belongs to the Section Mechanical Engineering)
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Abstract

In face milling one of the most important parameters of the process quality is the roughness of the machined surface. In many articles, the influence of cutting regimes on the roughness and cutting forces of face milling is considered. However, during flat face milling with the milling width B lower than the cutter’s diameter D, the influence of such an important parameter as the relative position of the face mill towards the workpiece and the milling kinematics (Up or Down milling) on the cutting force components and the roughness of the machined surface has not been sufficiently studied. At the same time, the values of the cutting force components can vary significantly depending on the relative position of the face mill towards the workpiece, and thus have a different effect on the power expended on the milling process. Having studied this influence, it is possible to formulate useful recommendations for a technologist who creates a technological process using face milling operations. It is possible to choose such a relative position of the face mill and workpiece that will provide the smallest value of the surface roughness obtained by face milling. This paper shows the influence of the relative position of the face mill towards the workpiece and milling kinematics on the components of the cutting forces, the acceleration of the machine spindle in the process of face milling (considering the rotation of the mill for a full revolution), and on the surface roughness obtained by face milling. Practical recommendations on the assignment of the relative position of the face mill towards the workpiece and the milling kinematics are given. View Full-Text
Keywords: face milling; surface roughness; acceleration; cutting force; relative position face milling; surface roughness; acceleration; cutting force; relative position
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited (CC BY 4.0).
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Pimenov, D.Y.; Hassui, A.; Wojciechowski, S.; Mia, M.; Magri, A.; Suyama, D.I.; Bustillo, A.; Krolczyk, G.; Gupta, M.K. Effect of the Relative Position of the Face Milling Tool towards the Workpiece on Machined Surface Roughness and Milling Dynamics. Appl. Sci. 2019, 9, 842.

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