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This study explores the relationship between endmill tool dynamics and cutting parameters, emphasizing the impact of these factors on machining dynamics, surface finish, and dimensional control. It introduces a novel approach to analyze and optimize the overall performance of a solid carbide endmill, with a specific focus on machining Aluminum 6066-T6. By using stability lobes diagrams (SLD), stable conditions for cutting were chosen, and then surface roughness and tool and workpiece vibration analyses were performed to assess machining performance. This work aims to understand the effects of operating below the peaks and valleys, inherent in the shape of the SLD, using different RPMs. The study's methodology involves tap tests using CutPro - Tap Test Module and milling tests on a horizontal machining center. The surface roughness measurement was performed using an Alicona Infinite Focus confocal microscope and accelerometers were positioned on the spindle bearing housing and workpiece. The findings suggest that within the stable range below the stability lobe diagram's boundary, there is a significant difference in vibration resulting in variation in surface roughness corresponding to the peaks and valleys of the SLD. The variation of acceleration, and consequently vibration, was considerably higher when operating below valleys which negatively affected the surface roughness of the workpiece. The surface roughness plays a pivotal role in tool performance and subsequently influences metal removal rate and tool and spindle life. For conditions closer to instability, this is even more important. In conclusion, this research lays the foundation for a holistic approach to solid carbide endmill design and cutting parameter selection, showing that the machining process can be optimized in terms of the SLDs, even in regions far below the stability limit / Thesis / Master of Applied Science (MASc)

The diploma thesis deals with determination of modal parameters for machine tool manage-ment. Experimental modal analysis is performed and a new method for determining the damping and stiffness of the machine tool guidance is proposed. A mathematical model for the calculation of signals using state equations was created and the damping stiffness was determined using hysteresis curves.

Regenerative chatter is a well-known machining problem that results in unstable cutting process, poor surface quality, reduced material removal rate and damage on the machine tool itself. Stability lobe diagrams supply stable depth of cut &amp / #8211 / spindle speed combinations and they can be used to avoid chatter. The main requirement for generating the stability lobe diagrams is the system dynamics information at the tool tip in the form of point frequency response function (FRF). In this work, an analytical model that uses structural coupling and modification methods for modeling the dynamics of spindle-holder-tool assemblies in order to obtain the tool point FRF is presented. The resulting FRF obtained by the model can be used in the existing analytical and numerical models for constructing the stability lobe diagrams. Timoshenko beam theory is used in the model for improved accuracy and the results are compared with those of Euler-Bernoulli beam theory. The importance of using Timoshenko beam theory in the model is pointed out, and the circumstances, under which the theory being used in the model becomes more important, are explained. The model is verified by comparing the results obtained by the model with those of a reliable finite element software for a case study. The computational superiority in using the model developed against the finite element software is also demonstrated. Then, the model is used for studying the effects of bearing and contact dynamics at the spindle-holder and holder-tool interfaces on the tool point FRF. Based on the results of the effect analysis, a new approach is suggested for the identification of bearing and interface parameters from experimental measurements, which is demonstrated on a spindle-holder-tool assembly. The model is also employed for studying the effects of design and operational parameters on the tool point FRF, from the results of which, suggestions are made regarding the design of spindles and selection of operational parameters. Finally, it is experimentally demonstrated that the stability lobe diagram of an assembly can be predicted pretty accurately by using the model proposed, and furthermore the stability lobe diagram can be modified in a predictable manner for improving chatter stability.