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Assessment of tool holder performance in roughing with end mills Correlation between in-process vibrations and surface quality: Abstract Tool holders are an important power train component of milling with shaft tools having a high impact on dynamic process behaviour and process results. This leads to a significant demand among industrial companies for scientifically proven methods to analyse tool holders which are easy to use as well. Different approaches were applied in order to meet these demands. The dynamic vibrational behaviour of different clamping mechanisms is investigated using tool holders of similar dimensions. First, the resonance frequencies of the tool holders are identified from dynamic compliance measurements in the machine tool. Subsequently, the dynamic process behaviour is investigated by peripheral milling tests in which vibrations of tool and tool holder are detected by acceleration sensors and microphones. Analysis of the sensor data and optical analysis of the manufactured surface reveal a significant influence of the particular clamping mechanism, superimposed by certain geometrical variations of the investigated tool holders. Chatter frequencies occurring during milling tests seem independent of the clamping mechanism respectively the particular tool holder and are caused by the tool or machine-tool components. They correspond roughly with the natural frequencies identified before. Chatter intensity and spindle speeds, at which chatter occurs, are influenced by the tool holders. The occurrence of chatter vibrations correlates with a significant drop in the surface quality of the workpiece. High resonance frequencies of the tool holder excited by chatter and low-frequency waviness observed on the machined surface are related. The well-known phenomenon can be explained under rough milling conditions by a 2D-model-based superposition of subsequent cutting edge engagements. This in turn may enable dynamic analysis and optimisation of rough milling operations by easy to use shop floor equipment in future. Keywords Tool holders · Dynamic behaviour · Surface formation · Frequency analysis · Shaft tools · Steel milling Investigated tool holder systems: alues. sured ic modal elated ell dynamic ools penhus onxhibited xpanxpandynamic adisek hanging mal or xire aritudied. o Fig. 7 Correlation between in-process vibrations fz = 0.04 mm/rev/tooth, ae = 7 mm , ap = 18 mm) surface quality. (Tool holder: ER-collet, n = 2708 − 5250 rev/min, APC with best results in comparison to other tool-holders: Test setup: Machine: Tool: Material: and MC12 by Gebr. Heller torus cutter, D=12, number of teeth=4 Steel, 42CrMo4 (1.7225) Cutting Parameter: n= 3979 rev/min fz= 0,04 mm/rev/tooth ae= 7mm ap= 18mm Fig. 1 Examples of the investigated tool holder systems Table 1 Main properties of the investigated tool holders 74 o spindle-side aces to ted ial capable to hout al. aces on ed el- Tool holder A mass m D1 bm [mm] [g] [mm] [mm] 92 100 90 1457 1274 1123 40 42 32 18 12.5 9 Modular Modular TS 90 918 24 8 Monolithic a Weldon 80 1120 42 15 Monolithic b APC ER HE a Full-periphery clamping b Point-line clamping Design ocess vibrations using Campbell diagrams based on acceleration sensor dat Monolithic a Fig. 6 Visualisation of in-process vibrations using Campbell diagrams based on acceleration sensor data. ( n = 2708 − 5250 rev/min, fz = 0.04 mm/rev/tooth, ae = 7 mm , ap = 18 mm) Rosenthal O. / Hintze W. / Möller C. (Published 08.01.2020 https://doi.org/10.1007/s11740-019-00944-w . Assessment of tool holder performance in roughing with end mills. Institute of Production Management and Technology, Hamburg University of Technology. Springer Nature) 75 Siege haben Gründe
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