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Ulular, Elcin

University of British Columbia

Shell face milling cutters are widely used in the industry for various machining applications for their efficiency in achieving a high material removal rate and superior surface finish. Particularly, larger diameter shell face mills with a high number of teeth can remove excess material from workpiece surfaces in a single pass. In this thesis, shell face milling cutters are mathematically modeled and design modifications are done during the cutter design phase to improve their chatter stability and productivity. The generalized mechanics and dynamics of shell mills are modeled for any given cutting condition, insert geometry, cutting coefficients, cutter workpiece engagement, and runout. The cutting force coefficients of AlSi12 work material are experimentally identified in both rake face (UV) reference frame and Radial-Tangential-Axial (RTA) coordinate frames and used in the process mechanics and dynamics models. The generalized model allows the prediction of cutting forces, torque, and power. The Frequency Response Function (FRF) of the cutter is obtained from Finite Element analysis of the digital model of the cutter and used to predict chatter stability and vibrations. The structural dynamics, cutting force prediction and chatter stability models are experimentally validated. The dynamic stiffness of the cutter is improved by design modifications which allowed the reduction of the mass and improved stiffness of the structural modes that affect the chatter stability. The thesis presents a systematic design, modification, and machining performance analysis of shell face mills in a digital environment to avoid costly physical trials.

Text

2024-02-21

Attribution-NonCommercial-NoDerivatives 4.0 International

http://hdl.handle.net/2429/87465

Mechanical Engineering

University of British Columbia

UBCV

http://creativecommons.org/licenses/by-nc-nd/4.0/