Effect of the Angle of Engagement and the Angle of Disengagement on the Chipping Failure of the Fly Cutter : Face Milling of Cylindrical Workpiece (2nd Report)

In this paper three components of the average cutting force and two components of the excited vibration of cutting force under the same cutting condition as in the 1st report are described. These forces are related to the angle of engagement (E.A.) and the angle of disengagement (D. E. A). Furthermore, it should be pointed out that the cutting force variation introduces the chipping failure of face milling cutter. A summary of the results is as follows. (1) The small variation of theoretical chip thickness seems to be the causes of non influence of E. A. and D. E. A. upon the average cutting force. But, these forces change according to the depth of cut and the feed per tooth. The appearance of tool failure due to chipping results in the vibration increase of the average radial cutting force. (2) The natural frequency of tool dynamometer used for this experiment is about 1300Hz. The sensitivity of this dynamometer is not enough to response the impact load at the time of engagement and disengagement. However, the vibration of cutting force at disengagement between +20° to +40° is large and the tool tip is apt to chip. (3) The tool failure due to chipping is affected remarkably by D. E. A. at the face milling of cylindrical workpiece.

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