Reliable scheduling in cutting conditions is very important in machining processes, and this requires thorough understanding of the physical behaviors of the machining process, which cannot be achieved without understanding the underlying mechanism of the processes. The book describes the mechanics and dynamics together with the clamping principles in milling processes, and can be used as a guideline for graduate students and research engineers who wish to be effective manufacture engineers and researchers. Many books have focused on common principles, which are suitable for general machining processes, e.g., milling, turning and drilling, etc. This book specifically aims at exploring the mechanics and dynamics of milling processes. Original theoretical derivations and new observations on static cutting force models, dynamic stability models and clamping principles associated with milling processes are classified and detailed. The book is indented as a text for graduate students and machining engineers who wish to intensively learn milling mechanism and machine tool vibration.

Preface ixIntroduction xiChapter 1 Cutting Forces in Milling Processes 11.1 Formulations of cutting forces 11.1.1 Mechanics of orthogonal cutting 11.1.2 Cutting force model for a general milling cutter 41.2 Milling process geometry 81.2.1 Calculations of uncut chip thickness 81.2.2 Determination of entry and exit angles 121.3 Identification of the cutting force coefficients 241.3.1 Calibration method for general end mills 241.3.2 Calibration method in the frequency domain 331.3.3 Calibration method involving four cutter runout parameters 391.3.4 Identification of shear stress, shear angle and friction angle using milling tests 481.4 Ternary cutting force model including bottom edge cutting effect 551.4.1. Calculations of FB(phi) 571.4.2. Calculations of FB(phi) 571.4.3 Calibration of Kqc (q = T, R) 581.4.4 Calibrations of Kq,B (q = T, R) 591.4.5 Experimental work 611.5 Cutting force prediction in peripheral milling of a curved surface 611.5.1 Calculations of instantaneous uncut chip thickness 651.5.2 Calculations of entry and exit angles 67Chapter 2 Surface Accuracy in Milling Processes 712.1 Predictions of surface form errors 712.1.1 Calculation of cutting forces and process geometries 732.1.2 Iterative algorithms of surface form errors 812.2 Control strategy of surface form error 892.2.1 Development of control strategy 892.2.2 Verification of control strategy 932.3 Surface topography in milling processes 952.3.1 Prediction method for flat-end milling 972.3.2 Prediction method for multi-axis ball end milling 101Chapter 3 Dynamics of Milling Processes 1153.1 Governing equation of the milling process 1153.2 Method for obtaining the frequency response function 1203.2.1 Derivation of calculation formulations 1213.2.2 Identification of model parameters 1343.3 Prediction of stability lobe 1393.3.1 Improved semi-discretization method 1393.3.2 Lowest envelope method 1443.3.3 Time-domain simulation method 155Chapter 4 Mathematical Modeling of the Workpiece-Fixture System 1654.1 Criteria of locating scheme correctness 1654.1.1 The DOFs constraining principle 1654.1.2 The locating scheme 1684.1.3 Judgment criteria of locating scheme correctness 1724.1.4 Analysis of locating scheme incorrectness 1734.2 Analysis of locating scheme correctness 1754.2.1 Localization source errors 1754.2.2 Fixture modeling 1764.2.3 Locating scheme correctness 1824.3 Analysis of workpiece stability 1864.3.1 Modeling of workpiece stability 1864.3.2 Solution techniques to the model of workpiece stability 1944.4 Modeling of the workpiece-fixture geometric default and compliance 2014.4.1 Source error analysis 2014.4.2 Workpiece position error 2074.4.3 Machining error analysis 2124.5 Optimal design of the fixture clamping sequence 2184.5.1 Effect of clamping sequence on high-stiffness workpiece 2184.5.2 Effect of clamping sequence on low-stiffness workpiece 2244.5.3 Optimization of clamping sequence 225Bibliography 229Index 245