Effect of tool setup imbalance on machined surface quality at end milling

Abstract

The purpose of the paper is to determine the model of surface roughness dependence on tool setup balancing accuracy and technological parameters of end milling. The research is based on the scientific foundations of the technology of engineering and cutting materials, mathematical modeling and active experiment. Scientific data are obtained using the following devices: a contact profilometer Taylor Hobson Form Talysurf i200, a balancing machine Haimer TD2009 Comfort Plus, a dynamometric complex Kistler 9253B23, a hardware and software complex CutPro for modal analysis, a device for tool measurement outside the machine-tool Zoller Genius 3. A mathematical model has been developed that reflects the effect of cutting modes and the value of toolset residual imbalance on surface quality. The performed regression analysis and the analysis of the model residuals confirm the correctness of model work. The surfaces of machined surface roughness response from the residual imbalance are obtained. The following machining parameters are chosen to be the factors: imbalance of the tool setup, feed, milling depth and width. The influence degree of each factor taken into account in the work is determined. The calculated and experimental data indicating the low influence of tool setup balancing accuracy on machined surface roughness are revealed. The only case when a slight deterioration of the surface state is observed is when the tolerances for balancing quality are exceeded several times. However, the surface quality corresponds to the surface after finish milling even at the maximum values of the factor x₁.