ADJUSTING OF PREFABRICATED FACE MILLS WITH INCLIMED CUTTING INSERTS
Abstract
The article deals with the problems of increasing the efficiency of adjustment prefabricated face mills containing inclined cylindrical cutting inserts. Rotation around its own axis is the main cutting motion during the operation of the face mill. When the mill rotates, centrifugal forces try to push the cutting inserts out of the mounting holes of the tool body. The influence of the number of revolutions of the mill on the magnitude of the centrifugal force that occurs during rotation is studied. Since the mill is equipped with cutting inserts with superhard material, the possible spindle rotation speeds during the operation of the mill are in the range from 850 to 2200 rpm, or (14 – 37) revolutions per second. As a result, diagrams of the desired dependencies were constructed for the face mill with a diameter of 315 mm, containing 48 cylindrical cutting inserts and having a cylindrical part diameter of D=8 mm, D=10 mm and D=12 mm, as well as a length of L=22 mm, L=35 mm and L=45 mm. The highest value (397 N) of centrifugal forces is reached at 37 revolutions per second for a cutting insert with D=12 mm and L=45 mm. The lowest values (89 N) are for an insert with D=8 mm, L=22 mm. Centrifugal forces can also be used to adjust the amount of protrusion of the cutting elements above the tool body. This can be implemented both for boring bars with a single cutter and for multi–blade metal–cutting tools, for example, single– and multi–stage prefabricated face mills. In this case, to adjust the face mill by centrifugal forces, it is enough to use spindle speeds much lower than the working ones, which is necessary to overcome the friction forces between the cutting inserts and the holes in the cutter body. Therefore, centrifugal forces will also have lower values than those found for the milling process by the tool. A method for adjusting a multi–stage face milling cutter with inclined cutting inserts is proposed, which allows taking into account the features of the functional purpose of different stages of the cutter. Steps on the inner surface of the ring gauge allow adjusting the cutting inserts of each stage to its size, which ensures a stepped distribution of the total machining allowance. Adjusting the cutting inserts of the finishing stage in the axial direction allows reducing the end runout of the cutting edges, which increases the quality of the surface machined with the milling cutter by improving the cleanliness of the machining. Adjusting the cutting inserts of the roughing stages in the radial direction allows reducing the radial runout of the cutting edges, which ensures their uniform wear and increases the durability of the cutting inserts. The proposed method also allows reducing the time for adjusting the face milling cutter containing a large number of cutting inserts.
References
2. Bullard, E. P. (1975). Preset Tooling. US Patent No. 3518769, B27g 23/00, U.S. CI. 33–185.
3. Chen, X., Wang, Q., Chen, W., Sun, J., He, Y., & Guo, H. (2024). Mining method for cutting force coefficient with the impact of tool vibration and machine tool system. Advances in Mechanical Engineering, 16(12), 1–9. https://doi.org/10.1177/16878132241308932
4. Dzhemelinskyi, V. V., & Lesyk, D. A. (2017). Osnovy profesiinoi diialnosti [Basics of professional activity]. KPI, Kyi'v, 177 (in Ukrainian).
5. Fan, M., Bi, Ch., Liu, X., Yue, C., & Hu, D. (2024). Effects of tool structure factor, cutting orientations, and cutting parameters of double–arc milling cutter on cutting force. The International Journal of Advanced Manufacturing Technology, 134(9–10):4701–4716. https://doi.org/10.1007/s00170-024-14375-0
6. Hlembotska, L., Balytska, N., Melnychuk, P., & Melnyk O. (2019). Computer modelling of power load of face mills with cylindrical rake face of inserts in machining difficult–to–cut materials. Scientific Journal of TNTU, 93(1), 70–80. https://doi.org/10.33108/visnyk_tntu2019.01.070
7. Hlembotska, L., Balytska, N., Melnychuk, P., & Vyhovskyi, H. (2021). Structural improvement of face mills designs based on systems approach. Scientific Journal of TNTU, 101(1), 102–114. https://doi.org/10.33108/visnyk_tntu2021.01.102
8. Hromovyi, O. A., Vyhovskyi, H. M., & Balytska, N. O. (2020). Shliakhy udoskonalennia protsesu obrobky ploskykh poverkhon detalei frezeruvanniam [Ways of improving the process of machining flat surfaces of parts by milling]. Technical engineering, 2(86), 48–53. https://doi.org/10.26642/ten-2020-2(86)-48-53 (in Ukrainian).
9. Hrytsenko, O. O., Basov, A. S., Orlov, R. O., & Kushnirov, P. V. (2024). Doslidzhennia zalezhnosti vidtsentrovykh syl vid kilkosti obertiv frezy [Study of the dependence of centrifugal forces on the number of revolutions of the milling cutter]. In: New and unconventional technologies in resource and energy conservation – Odesa National Maritime University, 21 (in Ukrainian).
10. Kushnirov, P. V., Dehtiarov, I. M., Yevtukhov, A. V., Rudenko, O. B., & Dumanchuk, M. Iu. (2019). Zbirni tortsevi frezy z rehulovanymy rizhuchymy vstavkamy [Prefabricated face mills with adjustable cutting inserts]. Compressor and power engineering, 4(58), 6–9 (in Ukrainian).
11. Kushnirov, P. V., Ivchenko, O. V., Ivanov, V. O., Neshta, A. O., Zhyhylii, D. O., Yevtukhov, A. V., Dehtiarov, I. M., Orlov, R. O., Dynnyk, O. D., Skabenok, M. M., & Kuiavinska, A. (2024). Tortseva freza z pidvyshchenym samohalmuvanniam tsylindrychnykh rizalnykh vstavok [Face mill with increased self–locking of cylindrical cutting inserts]. Patent of Ukraine No. 156499 (in Ukrainian).
12. Kushnirov, P. V., Stupin, B. A., Ostapenko, B. A., & Kasian, D. I. (2021). Analiz konstruktsii tortsevykh frez, shcho mistiat tsylindrychni rizhuchi vstavkyu [Analysis of Designs of Face Milling Cutters Containing Cylindrical Cutting Inserts]. In: International scientific integration ‘2021. «ISE&E» & SWorld in conjunction with KindleDP, 8, 6–9. https://doi.org/10.30888/2709-2267.2021-8 (in Ukrainian).
13. Kushnirov, P. V., Yevtukhov, A. V., Stupin, B. A., & Rudenko, O. B. (2018). Shliakhy zapobihannia vypadanniu rizalnoi vstavky z korpusu zbirnoi tortsevoi frezy [Ways to prevent the cutting insert falling out from the body of prefabricated facemilling cutter]. Compressor and power engineering, 3(53), 9–13 (in Ukrainian).
14. Kwak, Y. I., Bae, Y., Kurniawan, R., Jielin, Ch., Xu, M., Ali, S., & Ko, T. J. (2024). Influence of cutting–edge radius by an edge–honing process on the cutting tool life and coating. Journal of Mechanical Science and Technology, 38(2). https://doi.org/10.1007/s12206-024-0930-2
15. Melnychuk, P. P., Loiev, V. Iu., & Bohaichuk, O. M. (2013). Prystrii dlia rehuliuvannia vylotiv formoutvoriuiuchykh elementiv bahatolezovoho tortsevoho instrumenta [Device for adjusting the protrusions of the forming elements of a multi–blade end tool]. Patent of Ukraine No. 101774 (in Ukrainian).
16. Orlov, R. O., Kushnirov, P. V., & Basov, A. S.(2024). Nastroiuvannia rizhuchoho instrumentu vidtsentrovymy sylamy [Adjusting cutting tools by centrifugal forces]. In: Innovative technologies in Industry 5.0 – Sumy National Agrarian University, 14–15 (in Ukrainian).
17. Sandvik Coromant (2020) / Rotating tools – Milling, drilling, boring, tooling. – Sandvik Coromant catalog.
18. Vyhovskyi, H. M., & Hromovyi, O. A. (2020). Tortseva stupinchasta freza [Step–face mill]. Patent of Ukraine No. 140530 (in Ukrainian).
19. Vyhovskyi, H. M., Hromovyi, O. A., Balytska, N. O., & Hlembotska, L. Ie. (2021). Udoskonalennia protsesu chystovoho tortsevoho frezeruvannia ploskykh poverkhon detalei maloi shyryny [Improvement of the process of finishing face milling of flat surfaces of small–width parts]. Technical engineering, 1(87), 13–20. https://doi.org/10.26642/ten-2021-1(87)-13-20 (in Ukrainian).
20. Walter Prototyp (2022) Milling Tools for milling. – Catalog Walter, 288 p.
21. Zhang, X., Li, J., Li, X., & Li, Q. (2024). Cutting Characteristics and Reliability Analysis of Conical Picks Containing Prefabricated Grooved Rocks. Eksploatacja i Niezawodnosc –Maintenance and Reliability, 26(4). https://doi.org/10.17531/ein/191694
ISSN 
ISSN 
