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High-Definition Metrology Enabled Surface Variation Control by Reducing Cutter-Spindle Deflection

[+] Author Affiliations
Hai Trong Nguyen

Hanoi University of Science and Technology, Hanoi, Vietnam

Hui Wang

Florida State University, Tallahassee, FL

S. Jack Hu

University of Michigan, Ann Arbor, MI

Paper No. MSEC2014-4017, pp. V001T04A038; 9 pages
  • ASME 2014 International Manufacturing Science and Engineering Conference collocated with the JSME 2014 International Conference on Materials and Processing and the 42nd North American Manufacturing Research Conference
  • Volume 1: Materials; Micro and Nano Technologies; Properties, Applications and Systems; Sustainable Manufacturing
  • Detroit, Michigan, USA, June 9–13, 2014
  • Conference Sponsors: Manufacturing Engineering Division
  • ISBN: 978-0-7918-4580-6
  • Copyright © 2014 by ASME


This paper presents a method to reduce surface variation in face milling processes based on high-definition metrology (HDM) measurements. Our previous research has found and established the relations between surface variation patterns, cutting forces, and process variables. The findings revealed that varying feed rate and proper cutter path planning are the most feasible and cost-effective approaches for reducing variation along the feed direction. This paper explores the HDM data pattern that reflects surface tilting along the circumferential direction induced by cutter-spindle deflection. It is found that such a tilt is caused by the cutting load imbalance between the two sides of the cutter path. Cutting force modeling is then conducted to estimate such cutting load imbalance. Based on the model, a cutter load balancing algorithm is developed to reduce surface variations by adjusting cutter path and/or feed rate. A case study based on a cutting experiment is conducted to demonstrate that the proposed method can improve the surface flatness by 25%.

Copyright © 2014 by ASME
Topics: Metrology , Deflection



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