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A method for estimating the work of cutting forces to improve the efficiency of face milling of large-size workpieces
Abstract
The paper presents a method of vibration reduction during flat surface milling of large-sized details. It involves searching for the best conditions for mounting the workpiece based on the experimental identification of impulsively excited dominant vibration amplitudes, corresponding natural frequencies and phase angles on the selected machined surface. The identification is repeated for a set of tightening torques for the mounting screws. Then, by estimating the minimum work of cutting forces along the width of the cut layer, the best clamping of the workpiece can be predicted. The use of the method does not require the development of any calculation model for computer simulations. It leads to increased production efficiency by improving the product quality, shortening the production time, and reducing costs. Improving the product quality has been evidenced by assessing the root mean square (RMS) of vibrations in the time domain during flat milling, as well as by assessing the machined surface quality (roughness) and its geometric accuracy (flatness deviations). Shortening production time and reducing costs demonstrate the profitability of the method as well. The method enabled the precise identification of the best conditions for mounting the workpiece, as a result of tightening the securing supports with a torque of 50 Nm. The above classifies the obtained products even in the category of those made using grinding methods, without the need to implement the latter. Due to the significant reduction in environmental pollution and power demand, the proposed method meets the expectations of environmentally friendly, so-called green technologies.
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- Category:
- Articles
- Type:
- artykuły w czasopismach dostępnych w wersji elektronicznej [także online]
- Published in:
-
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
pages 1 - 21,
ISSN: 0268-3768 - Language:
- English
- Publication year:
- 2025
- Bibliographic description:
- Kaliński K., Galewski M., Stawicka-Morawska N., Mazur M., A method for estimating the work of cutting forces to improve the efficiency of face milling of large-size workpieces, INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY, 2025,10.1007/s00170-025-15310-7
- DOI:
- Digital Object Identifier (open in new tab) 10.1007/s00170-025-15310-7
- Sources of funding:
-
- Free publication
- Verified by:
- Gdańsk University of Technology
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