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  • The modeling of surface tex...
    Melkote, Shreyes N

    01/1993
    Dissertation

    Current emphasis in manufacturing industries is on achieving higher levels of product quality. For machined parts, the surface texture constitutes one of the most important aspects of product quality that often determines its functional characteristics. In order to accomplish the goal of producing parts conforming to the functional requirements, it is necessary to gain a better understanding of the surface generation mechanism. The focus of this thesis is on developing analytical models to describe the surface texture generated in the end milling process. This process is widely used in the aerospace industry to machine a wide range of work materials and complex geometrical shapes. Models are developed for predicting the two- and three-dimensional surface texture generated in peripheral and slot end milling. These models incorporate the ideal effects of tool geometry and process kinematics, and non-ideal effects of cutter/spindle runout, cutter flexibility, and tool wear. Model verification is performed through actual machining experiments. Significant improvements in the prediction of the slot floor surface geometry are obtained by explicitly modeling the effects of the radial rake and the end tooth relief angles. It is shown that, in general, these angles are important and, depending on their magnitudes, can affect the surface texture parameters greatly. The effect of end mill flexibility on the slot floor surface texture is examined in detail. It is found that the extent to which back-cutting impacts the floor surface texture is governed by the compliance of the end mill. The effect of tool flank wear on the surface texture produced in peripheral end milling is investigated experimentally and a preliminary model presented. A computer-based framework to study certain functional properties of machined surfaces in a tribological environment is also described. The utility of this framework is demonstrated through the use of end milling surface texture prediction models developed in this thesis.