Experimental Optimization of Cutting Modes for Milling Based on Vibroacoustic Analysis

The paper proposes a method for setting the cutting parameters for metal-cutting machines. This method is based on performance estimation and a vibroacoustic analysis of the cutting process. Before experiments are carried out, a three-dimensional finite-element model of the machine is built, and then the NX Advanced Simulation module is used to calculate the actual machine frequencies. First, we set the basic and the maximum values of the cutting parameters. Then, we build an experimental matrix and carry out the experiments on its basis. The matrix is based on a Taguchi method to reduce the number of necessary experiments. The experiment is designed to find out the maximum amplitude as well as the maximum amplitude frequency of vibroacoustic oscillations. Then, we estimate experiment-specific performance. Further, we set the optimal cutting parameters to ensure the maximum performance and vibration stability of the cutting process. This is done by reference to the Harrington desirability function. The method is versatile and applicable to any machine or material.