END MILL TOOLING SETUP UNIFICATION BY EXTENSION LENGTH UNDER CONTOUR MILLING OF PRODUCTION TOOL PLANES

Abstract

The PURPOSE of this research is to reduce the product changeover time in singular manufacturing with a broad range of products. METHODS. An approach is presented that includes tooling setup unification by the end mill extension length. The calculation model allowing for the tool extension length effect on deflection is designed by the finite element method. To obtain the probable deflection of the end mill and determine its influence on the contour accuracy without calculations a nomogram is constructed, the results of the intermediate calculations are decomposed into quadrants, and the final result of deformation is given with regard to the corrections obtained when solving the finite elements of the models of all the combinations under investigation. RESULTS AND THEIR DISCUSSION. A nomogram for deflection determination has been constructed. An experiment using a 676P milling machine has been carried out to determine a correction factor for end mill deflection. CONCLUSIONS. The use of the nomogram allows to determine tool deflection without calculations and perform tooling setup unification by the end mill extension length that will provide the required precision of dimensions and reduce the product changeover time.