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DOI 10.1007/s00170-013-5356-4
ORIGINAL ARTICLE
Abstract In this study, the effects of cutting forces on the Keywords Chatter vibration . Finite element method .
support of horizontal woodworking milling machine are ex- Horizontal milling machine . Support for machining . Failure
amined during profile cutting process using both experimental analysis
and analytical approaches. The support modeled in 3D using
SolidWorks software is a crucial component of the horizontal
milling machine used to locate and fix the wood workpiece 1 Introduction
during the cutting process on the workbench. The effects of
cutting forces on the support specimens are measured exper- Horizontal milling machine taken into account in this study is
imentally considering vibration and failure analyses. Analyt- a woodworking milling machine which is named based on the
ical stresses and modal analyses of the support were also cutting tools and workpiece materials. In the milling ma-
calculated using finite element-based analysis approach. Chat- chines, profile cutting tool cutting processes are generally
ter vibration forces of the cutting tool which resulted from used and performed horizontally so that it is called horizontal
cutting forces in x -, y -, and z -directions were calculated profile milling machines. They work as semi- or full automatic
analytically during the profile cutting process. The results according to their working conditions and cutting principles,
showed that both cutting and chatter forces are highly effec- e.g., workpieces are controlled manually in the semiautomatic
tive on the support component failure of the woodworking milling machines of which motor and shafts are mounted
milling machines. under the workbench. Using these machines, many different
types of cutting processes such as grooving, cordon, chamfer,
boss, etc. can be performed easily. In these processes, the
workpieces are located on the workbench and propped up
the support to the cutting forces since these forces are trans-
K. Gok (*)
ferred to the support through workpiece. The support, one of
Technical Science College, Department of Machine and Metal
Technologies, Dumlupinar University, Kutahya 43100, Turkey the most important parts of these machines, is used to provide
e-mail: kadirgok67@hotmail.com stationary or adjusting positions of the workpieces on the
workbench. The cutting tools are producing orthogonal cut-
E. Turkes
Department of Mechanical Engineering, Dumlupinar University,
ting forces along with chatter forces that cause stresses and
Tavsanli Yolu 10 Km, Kutahya 43100, Turkey deformations on the workpiece and support. These forces are
e-mail: eturkes@dpu.edu.tr absorbed by the workpiece and support during the cutting
process.
S. Neseli
No available studies in literature about the design failure of
Technical Science College, Department of Machine and Metal
Technologies, Selcuk University, Konya 42003, Turkey the supports had been done for the woodworking milling
e-mail: sneseli@selcuk.edu.tr machines, but few studies are appearing about fixture design
and portal tie rod support. Bonjak et al. [1] studied on the
Y. Kisioglu
failure analysis of bucket wheel excavator portal tie rod sup-
Department of Mechanical Education, Kocaeli University,
Umuttepe Campus, Kocaeli 41000, Turkey port using finite element method (FEM) simulations,
e-mail: ykisioglu@kocaeli.edu.tr Momcilovic et al. [2] worked on the failure of 28-MW
Int J Adv Manuf Technol
horizontal hydro-turbine shaft based on the failure criteria 2.1 Definition of cutting forces
using numerical approach, and Bayrakceken et al. [3]
performed fracture failure analysis of a camshaft of an auto- During the profile cutting process, the cutting forces on the
mobile engine using the FEM approach. There is no specific workpiece occur when the cutting tool plunges. The work-
study interested in the support failure analysis of the horizon- piece is located in the workbench and the cutting tool is
tal milling machines for the woodworking process. positioned in the coordinate system of the milling machine
In this study, the support of the woodworking horizontal as seen in Fig. 2. These cutting forces are generally defined as
milling machines subjected to orthogonal cutting and chatter compressive forces applied to the workpiece during the cut-
forces is analyzed using both experimental and numerical ting process. As seen from Fig. 2, the normal compression
approaches. Experimental studies were carried out using three (P n) and the feeding (P fd) forces are exerted in z- and x-
support specimens at a small woodworking engineer's work- directions, respectively. The tangential cutting force (P c) is
shop. The cutting forces are simulated using the finite element distributed to effect in both x- and y-directions. The frictional
analysis (FEA) method to calculate the stresses which oc- force (P f) is exerted in x-direction, opposite direction of the
curred on the support. The modal analysis of the support cutting, during the cutting process. The vectoral summation of
subjected to cutting and chatter forces is also performed by a these forces can be written as follows:
hammer impact using CutPro 8 software. Obtained results
Pfd Pc P f 1
from both FEA simulations and modal analyses are compared
with corresponding experimental results. P f Pn 2
tool and workpiece vibrations on the instantaneous tooth feed. static part (s t sin j ), attributed to rigid body motion of cutter,
The model of the toolworkpiece structure is then presented and a dynamic component caused by the vibrations of the tool
and the numerical parameters for a particular toolworkpiece at the present and previous tooth periods. Since the chip
structure are also given. The stability analysis technique de- thickness is measured in the radial direction (v j ), the total chip
rived by [6] for linear force processes is summarized. Milling load, h ( j ), can be expressed as follows:
cutters can be considered to have two orthogonal degrees of
freedom (DOF), as shown in Fig. 4, in either metal or wood h j st sin j v j;0 v j g j 3
cutting process. The cutter is assumed to have a number of
teeth, N , without helix angle. The cutting forces motivate the where s t is the feed rate per tooth and (v j,0, v j ) are the dynamic
structure to move in x- and normal y-directions that cause displacements of the cutter at the previous and present tooth
dynamic displacements in x - and normal y-directions, respec- periods, respectively. The function g( j ) is a unit step func-
tively [7]. tion that determines whether the tooth is in or out of cut that is
The dynamic displacements are carried out in rotating tooth in the following conditions:
number j in the radial or chip thickness direction with the
coordinate transformation of v j =x sin j y cos j , where j g j 1 st < j < ex
is the instantaneous angular immersion of tooth j measured
clockwise from the normal y -axis. If the spindle rotates at an
angular speed of (rad/s), the immersion angle varies with g j 0 j < st or j > ex 4
time as j (t)= t. The resulting chip thickness consists of
where sts and ex are the start and exit immersion angles of
the cutter to and from the cut, respectively. Henceforth, the
static component of the chip thickness (s t sin j ) is dropped
from the expressions because it does not contribute to the
dynamic chip load regeneration mechanism. Therefore,
h j xsin j ycos j g j 5
F tj K t a h j X
6 At Ar eirt 11
F rj K r F tj r
Z
1
where K t and K r are the constant cutting coefficients. Ar At eirt dt
Resolving the cutting forces in x- and y-directions,
0
F xj F tj cos j F rj sin j
7 The number of harmonics (r) of the tooth passing frequency
F yj F tj sin j F rj cos j
() to be considered for an accurate reconstruction of [A(t)]
Summing these forces considering all teeth, the total dynamic depends on the immersion conditions and number of teeth in
milling forces acting on the cutter can be rewritten as follows: cut. In the most simple approximation, the average component
of the Fourier series expansion is considered (i.e., r =0), then
X
N 1
Fx F xj j 8 Z
1
j0 A0 At dt 12
X
N 1
0
Fy F yj j
j0
Since [A 0] is valid only between the entry ( st) and exit
where j = +j p and cutter pitch angle is p =2 /N . ( ex) angles of the cutter (i.e., g( j )=1) and the j = t and
Substituting chip thickness (5) and tooth forces (8) into (9)
and rearranging the resulting expressions in matrix form yield
as follows:
Fx 1 a axy x
a K t xx 9
Fy 2 ayx ayy y
p = , it becomes equal to the average value of [A(t)] at factors must be considered and the resulting stability expres-
cutter pitch angle p =2/N: sion must be solved with numerical iterations [6]. The chatter
predictions are investigated for the orthogonal cutting in the
Zex
milling process as seen in Fig. 5. Machine chatter vibrations
1 N xy
A0 Ad xx 13 are predicted in orthogonal cutting with 2 DOF milling system
p 2 yx yy
st by analytical form.
The equations of motion of the cutting system in the feed
where the integrated functions are given as follows: direction (x) and (y) were formed as follows:
1 1
xx cos 2 2K r K r sin 2exst xy sin 22 K r cos 2exst
2 2 mxj xt cxj xt k xj xt F rj
1 1
yx sin 2 2 K r cos 2exst yy cos 22K r K r sin 2exst 15
2 2 myj yt cyj yt k yj yt F tj
The average direction factors are dependent on the radial
where m x and m y are the mass, c x and c y are the damping, and
cutting constant (K r ) and the width of cut bound by entry ( st)
k x and k y are the stiffness coefficients of the jth tooth. The
and exit ( ex) angles. The dynamic milling expression in
simultaneous vibrations in the x 1 and x 2 directions are excited
Eq. 10 is reduced as follows:
by the cutting forces F x1 and F x2 , determined by the
1 following expression:
f F t g aK t A0 ft g 14
2
F x1 F x sin 1 F y cos 1
16
where [A 0] is the time-invariant but immersion-dependent F x2 F x sin 2 F y cos 2
directional cutting coefficient matrix. Since the average cut-
ting force per tooth period is independent of the helix angle, where F x and F y are cutting forces obtained by decomposing
[A 0] is valid for helical end mills as well. Fourier coefficient the cutting (radial) force F r and the thrust (tangential) F t
[A 0] may not be sufficient for accurate prediction of chatter into the corresponding direction, given by the following
stability. In such cases, higher harmonics of the directional expression:
F x F r cos F t sin
Table 1 Outputs of the impact hammer and microphone tests for cutting 17
system F y F r sin F t cos
Direction m x,y [kg] f nx,y [Hz] k x,y [N/m] x,y [%] f c [Hz] where is the variation of rake angle 0 or the clearance
6 1 angle . Due to the oscillation of the tool in wave cutting
x 0.352 597.37 4.96410 1.02210 650
y 0.411 621.77 6.266106 1.993102 surface, the rake angle, 0, and the clearance angle, , can
be expressed as follows:
Int J Adv Manuf Technol
y s coss 0
0 0 tan1 Ft a h a h j Kt
v
18
sinc cosc s 0
y s sin s 0
0 0 tan1 Fr a h a h j Kr Ft Kr
v sinc cosc s 0
21
where y is the velocity of the tool vibration in the y-direction
and v is the cutting speed. The cutting force, F r, and the thrust where s is the shear stress, s is the average friction angle,
(tangential) force, F t , described in [6, 10] can be reexpressed and c is the shear angle. The radial force F r is assumed to be
as follows: proportional to the tangential force with a ratio of K r =F r /F t =
tan( s 0).
F tj K t a h j Rcos0 3.1 Analysis of profile cutting system
19
F rj K r F tj Rsin0
The milling stability analysis, orthogonal cutting model de-
veloped by Koenigsberger and Tlusty [11], is used consider-
where R is the resulting cutting force and defined as follows:
ing the average direction of the cut. But Tlusty and Ismail [12]
showed that the time domain simulations would be required
q
2 2 for an accurate stability prediction in milling process. Sridhar
R F rj F tj 20 et al. [13, 14] performed a comprehensive analysis of milling
stability which involved numerical evaluation of the dynamic
The orthogonal F r and thrust F t forces can also be rewrit- milling system's state transition matrix. Minis et al. [9] and
ten as follows: Minis and Yanushevsky [15] used Floquet's theorem and the
Fourier series for the formulation of the milling stability and the workpiece is designated as K t =1.510+ 8 N/m2. The
numerically solved it using the Nyquist criterion. Budak [16] diameter, cutting width, and attach length (L ) of the cutting
developed a stability method which leads to analytical determi- tool are taken as 50, 40, and 60 mm, respectively. The number
nation of stability limits. The method was verified by experimen- of cutter teeth with a zero helix angle is taken as 3. The chatter
tal and numerical results and demonstrated to be very fast for the frequencies (f c [Hz]) given in Table 1 were obtained using
generation of stability lobe diagrams [6, 17, 18]. This method LabView 7.1 software. Experimental modal analysis of cut-
was also applied to the stability of ball-end milling [19]. ting system was performed by measuring the transfer func-
tions using hammer, force transducer, and accelerometer at-
3.2 Modal analysis tached to the milling machine. The accelerometer used in the
test measures weighs in the range of 50 g with the sensitivity
In this study, the modal analysis of the support is performed of 104.3 mV/g considering the resonance frequency of
considering the orthogonal cutting process having 2 DOF. 40.0 kHz, and the hammer impact force ranges from 0 to
Values of equivalent mass, stiffness coefficient, damping ratio, 500 N with the impulse sensitivity of 10 mV/N.
and natural frequency of the cutting system are calculated by The equivalent mass m x ,y, stiffness coefficient k x ,y ,
the modal analysis. The measurement of the chatter frequency damping ratio B x,y, and natural frequency f nx,y of the support
is performed by a microphone test as shown in Fig. 6 and the (see Table 1) are feed in both x- and tangential y-directions,
corresponding values are given in Table 1. respectively. The chatter frequency of the cutting system is
The transfer function of the cutting systems is calculated designated as f c . The specific cutting force, K [N/m2], for a
for the milling machine considering the different spindle stability analysis is the most important criterion for the exper-
speeds [rotations per minute]. The maximum axial depth of imental matrix. According to Porankiewicz et al. [20], it is also
cut [millimeter] for the chatter vibration-free machining is very important to get the proper kind of variable influence for
obtained from the dynamic cutting tests. When the spindle the incomplete experimental matrices. The choice to use a
speed increases, the values of (a lim) decrease since PDR simpler model is expected to result in decreased approxima-
decreases as well. tion quality and also reversing the impact of lower importance
The modal analysis of the cutting system is performed by a variables. It must also be pointed out that the statistical rela-
hammer impact using the CutPro 8 software as seen in Fig. 7. tionships outside the ranges of independent variables chosen
The specific cutting force for the dried oakwood material of in the experimental matrix are not valid. For some functions
without interactions, points lying outside an analyzed range of of the instantaneous cross-sectional area of the chip and spe-
independent variables are charged by errors in a meaningful cific cutting force K . If the condition does not meet, the
degree that would not have been large enough to affect pre- process of cutting itself is already nonlinear and as such
dictions made within the range of the data. Any additional practically impossible to analyze [21]. From the aspect of
justification for a choice of a certain type of function makes the manner of excitation and response of the structure of the
sense, in authors opinion, if the data exists from additional machining system, the process of periodic circular cutting of
experiments carried out under the same machining conditions. wood tissue usually does not meet the requirements of closed-
Hence, the specific cutting force, K , can be calculated as loop systems. The system consists of specific periodic forced
follows: excitation and self-excitation which is interacting mutually or
modulating the cutting force to determine the initial conditions
K c1 eP c8 P c2 F c3 f R c4 bF5 f cR6 c7 of each subsequent cut. The correlation between the specific
22 cutting force K and the rotational angle of the tool was
determined experimentally and introduced into the simulation
where b k and c k are k estimators evaluated in statistical program in [23]. The only parameter which changed during
model, F is cutting angle, and f R is feed per revolution simulation of the cutting process was the angle that is
[millimeters per revolution]. The specific cutting force, K , is defined between the tool and the workpiece. The changes of
used in rather old literature for wood machinability character- this angle affect the changes in specific cutting force. Addi-
ization; nevertheless, in the present work, it was taken into tionally, according to [24], if the average tangential compo-
account for comparison with the literature. The estimators nent of the cutting force is expressed in the form F t =K t A hm ,
were evaluated for dependence between the specific cutting then the specific cutting force can be expressed as follows:
force K and the cutting angle F and the feed per revolution,
f R , according to formula given in [21]. Hence, the specific Ft
Kt const: 23
cutting force K decreasingly dropped with increasing rate of Ahm
feed per revolution f R and increasingly fell with enlargement
of the cutting angle F. Furthermore, according to Bucar [22], where the coefficient A hm represents the influence of the mean
due to the fact that in the cutting process, the cutting or cross-sectional area of the chip. The coefficient of the mean
exciting force also depends on relative displacements between cross-sectional area of the chip is expressed as a product of
the tool and workpiece. The dynamic model has been set up as a h cm , and the specific cutting force at a condition of 0<c<1
nonlinear where the exciting force is merely the consequence can be expressed as follows:
Ft
Kt 24
ahcm
Fig. 17. The maximum equivalent stress obtained is about 2. Momilovi D, Odanovi Z, Mitrovi R, Atanasovska I, Vuherer T
(2012) Failure analysis of hydraulic turbine shaft. Eng Fail Anal 20:
1.897 MPa which is lower than the ultimate tensile strength of
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damaged region are also calculated in the x- and y -directions. camshaft made from nodular cast iron. Eng Fail Anal 13(8):1240
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4. lhan R, Burdurlu E, Baykan (1990) Cutting theory in woodworking
directions are obtained about 0.789 and 0.486 MPa,
and furniture industry machines, 3rd edn. Our Office Publications,
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milling. CIRP Ann Manuf Technol 44(1):357362
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the woodworking horizontal milling machine broken consis- ics, machine tool vibrations, and CNC design. Cambridge University
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since the geometry of the support is not feasible. In order to in milling-part I: general formulation. J Dyn Sys Meas Control
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