Untersuchungen zum dynamischen Stabilitätsverhalten von Fräswerkzeugen zur HSC-Bearbeitung

(Investigation of the Dynamic Stability Behavior of Milling Tools for High Speed Machining)

Enk, D.

This thesis describes the results of experimental investigations concerning the dynamics of milling processes using long, slender end mills, which consist of tungsten carbide, like they are often used in HSC machining. Due to the versatile applications of HSC milling in machining technologies, especially in the machining of free-formed surfaces, the investigations are carried out with the main goals to improve the precision of stability predictions and to gain process understanding.

After discussing the state of the art in the analysis of machining dynamics and prediction of process stability, the measuring and modeling of the dynamic properties is conducted in relation to the spindle speed and the diameter and length-to-diameter ratio of the tool. By incorporating the developed model into the stability analysis, it is possible to enhance the precision in predicting stable rotational-speed ranges.

To expand the existing knowledge concerning the dynamics of cylindrical end mills, the examination of the process behavior with changing engagement conditions is performed in addition to the analysis of the influence of additional contact between the face side of the tool and the groove bottom of the workpiece on the dynamical behavior of the process.

The last focus of this thesis is the examination of the transferability of models to predict the process stability, which deliver good results when applied to cylindrical end mills, on applications of ball end mills and toroidal end mills. The analysis and the discussion of potential reasons for differences between the prediction and the actual stability behavior of these tool types conclude this work.

Published as

Dissertation Technische Universität Dortmund, Vulkan Verlag, Essen, 2009, ISBN 978-3-8027-8748-5