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<p>Disturbance factors, such as self-excited tool vibrations, limit the performance of modern machining processes and thus restrict the quality, productivity, and sustainability of industrially manufactured components. Tools with functional flank-face structures as well as asymmetric dynamic properties represent two approaches that are capable of reducing such dynamic disturbances. Since up to now both approaches have solely been investigated separately, a hybrid concept was developed, applied, and evaluated that combines both techniques and exploits synergistic effects. It was shown that the compliance of milling tools can be specifically adjusted by appropriate dimensioning of laterally inserted grooves on the tool shank. In addition, a preparation of the cutting edges, e.g. applying surface structures, are still feasible. The effect of such a hybrid tool modification was evaluated based on in-process measurements and workpiece analyses. An increase of the process stability and, thus material removal rate of 85% compared to non-modified tools could be achieved, which also exceeded the stabilizing potential of tools that include only one modification approach.</p>

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Fundamental investigation of process stabilization through combined modification of milling tools with structured functional surfaces and asymmetric dynamic properties

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年1月8日

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  • Rafael Garcia Carballo,
  • Jonas Baumann,
  • Simon Jaquet,
  • Dirk Biermann

摘要

Disturbance factors, such as self-excited tool vibrations, limit the performance of modern machining processes and thus restrict the quality, productivity, and sustainability of industrially manufactured components. Tools with functional flank-face structures as well as asymmetric dynamic properties represent two approaches that are capable of reducing such dynamic disturbances. Since up to now both approaches have solely been investigated separately, a hybrid concept was developed, applied, and evaluated that combines both techniques and exploits synergistic effects. It was shown that the compliance of milling tools can be specifically adjusted by appropriate dimensioning of laterally inserted grooves on the tool shank. In addition, a preparation of the cutting edges, e.g. applying surface structures, are still feasible. The effect of such a hybrid tool modification was evaluated based on in-process measurements and workpiece analyses. An increase of the process stability and, thus material removal rate of 85% compared to non-modified tools could be achieved, which also exceeded the stabilizing potential of tools that include only one modification approach.