Intermittenta flereggsprocesser : modeller och metoder för belastningsanalys

Sammanfattning: This thesis presents the developement and verification of cutting force models for multi-toothed cutting processes. The scope of the thesis includes the modelling and measuring of factors that affect the mechanical load variation between individual cutting edges in the process. These factors will for example influence tool life and workpiece quality. The most important factors are; errors in radial and axial cutting edge position, tool dynamics, tool wear and force induced variations in cutting data. In order to verify the force models it is necessary to measure the cutting force on each specific cutting edge. This is achieved with a newly developed milling force sensor, based on strain gauges, where 8 force components can be measured simultaneously directly on the tool. During the bandsaw experiments a specially developed workpiece geometry is used to measure and identify the cutting forces on each cutting edge. The experimental work shows that it is possible to accurately measure and separate cutting forces acting on a specific edge during face milling and bandsawing. The variation in mechanical load between different edges is mainly due to the errors in radial and axial cutting edge position, but also the process dynamics. The deflection of the tool is of some importance in milling operations. The variation of cutting forces will affect the wear rate of the edge. As the result of this, a succesively worn tool shows smaller variations in cutting forces between edges.The experimental results generally show a very good agreement with the developed cutting force models.