Comparative study on the critical effect of radial rake angle and machining parameters on the formation of vibration amplitude during end milling of Nimonic 263

摘要

The chatter during machining process has a profound effect on the surface quality, power consumption, tool and machine failure and it is applied to a various machining processes such as turning, milling and grinding. The objective of this paper is to validate the influence of tool geometry and machining parameters such as cutting feed, cutting speed and Radial Rake Angle (RRA) of end mill cutter (- 7 degrees, 0 degrees and 7 degrees) on the induced vibration or acceleration amplitude during end milling using statistical tool. Because, the formation of this vibrations have resulted to cause critical effects such as reduction in tool life, lowest surface finish. For conducting experiments, L27 orthogonal array has been employed. The experiment has been conducted on Nimonic 263 using TiAlN coated Tungsten carbide tool and Tri-axial accelerometer (Model:7543A). Statistical tool such as Regression and Analysis of variance are employed to develop a mathematical model and predict optimum parameters and the data analysis confirmed that the cutting speed has a dominant effect on vibration amplitude followed by tool nomenclature and cutting feed.