A STUDY ON THE MODELING OF TOOL MOTION AND HIGH-ACCURACY SURFACE GENERATION BY THE USE OF CUTTING-FORCE SIGNALS

Abstract

The process of creation of a typical machined surface is treated here as a dynamic system. An investigation is carried out to establish a relationship between the characteristics of the cutting-force fluctions that cause vibratory response of the tool - workpiece system and the formation of the surface, in face cutting using a sintered-carbide cutting tool. The cutting force is measured and analyzed in the frequency domain. The power spectral densities of the cutting force give useful information on surface generation and can be used to determine the control factor of the surface roughness. The terms, PSD ratio and normalized spindle frequency PSD, are defined and when the power in the spindle frequency is larger than that in other frequencies but absolutely low, the high accuracy surface roughness is obtained. The aim of this research is to determine the surface profile from the measured and analyzed cutting-force signals. The simulation of surface generation gives the comprehension of its mechanism and helps in the prediction and the control of the surface quality. Considered in this paper, is how the cutting-force signals affect the surface generation and how better surfaces can be acquired.