Investigating the impact of chucks on the stability of a milling process

The impact of a tool chuck on the dynamic stability of a milling process with an end mill was investigated using a workpiece made of aluminium wrought alloy V95pchT2. To assess the dynamic stability, we analysed a Fourier transformed signal recorded during milling using a Shure PGA81 -XLR tool directional microphone. The milling was performed on an HSC75 linear high-production machining centre with an H10F solid carbide end mill. Cutting conditions were calculated based on a stability diagram derived from an operational modal analysis of a manufacturing system. The surface roughness was measured with a Taylor Hobson Form Talysurf i200 contact profilometer. Performance defined by the rate of material removal and the roughness of a treated surface was used to evaluate the cutting process. A correlation was found between the type of tool chuck fixating the end mill, the rate of material removal and the roughness of the machined surface. It was found that, for milling using a power chuck, the areas of stable cutting correspond to the max imum cutting depth equal to 5.6 mm at a cutting width of 16 mm and a cutting feed of 0.1 mm/rev. However, for the other studied chucks, this indicator was 20 to 30% lower. End milling conducted using a power chuck with a solid carbide cutter with a diameter of 16 mm and three cutting teeth resulted in dynamically stable cutting with the highest material removal rate (575.6 cm3/min) and minimum surface roughnes s (0.56 μm). Based on the conducted analysis, for the operation of end milling on a machine with computerised numerical control (CNC), a power tool chuck is recommended that improves milling performance by over 25% relative to the considered tool setups. Furthermore, this preserves the quality of a treated surface and increases the tool cutting life owing to dynamically stable cutting.

clamping chuck, power chuck, vibrations, dynamic stability, modal analysis, end mill