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This paper adopts composite structure system analysis method to perform modal analysis of high-speed face milling cutter which is mounted on the machine tool through FEM modal analysis. The key problem of this method is to obtain joint surface parameters between the machine tool spindle and face milling cutter through experimental modal analysis and MATLAB software. The joint surface parameters consist of linear stiffness, linear damping, rotation stiffness and rotation damping. After getting the frequency response function (FRF) at the tool tip of the face milling system through experimental modal analysis, the contact surface parameters can be used to eliminate the influence of the machine tool to get modal parameters of the face-milling cutter itself. Based on the finite element model of face milling cutter, composite structure system analysis method can be used easily to acquire the dynamic performance of the face milling system through FEM modal analysis, greatly to improve the reliability of modal analysis, and is helpful to the dynamic design and the structure improvement of high speed face milling cutter.

The paper presents rigorous experimental validation results of the algorithm to predict work-piece surface roughness in face milling operation as developed in the Part 1. The experimental verification system consisting of various devices was established according to the given experimental conditions. Experimental parameters are set for steady face milling. Experimental data are collected through four experiments. These experimental data include the axial and radial run-out errors of each square insert with flat edge, the modal parameters of the face milling system, the Z-axial milling force and the measured surface contour of the milled work-piece. The trajectory of cutting teeth is calculated by the MATLAB software based on the static surface roughness model. Z-axial dynamic relative displacement between the tooth and the work-piece is obtained as the predicted dynamic surface roughness. By integrating the prediction results of static and dynamic models, the surface contour is predicted. Predicted and measured results are compared in the same figure and basically consistent. The work-piece surface roughness prediction model will be useful and valid in high-speed face milling.

The work-piece surface quality reflects the cutting performance of face-milling cutter. This paper presents the development of an algorithm to predict work-piece surface roughness in face milling operation. The prediction model is based on the face milling cutter fixed square inserts with flat edges. The static prediction model considers the effects of radial and axial run-out error of inserts, feed per tooth, tooth number, cutting edge length, nose radius, main lead angle, and axial depth of cut. The dynamic prediction model considers the effects of the Z-axial relative displacement between the work-piece and cutting teeth caused by forced vibration. By combining the prediction results of static and dynamic models, the surface roughness of the work-piece in face milling is predicted.

In this paper, a face-milling tool system is dealt with the Finite Element Modal Analysis (FEMA) using advanced contact technology functionalities. Dynamic characteristics analysis is performed and the stiffness contribution is included in the modal pre-stressed analysis. Natural frequencies and mode shapes of vibration are calculated. The FEMA is followed by experiments performed for different operating conditions of the face-milling system. The dynamic characteristics obtained in this paper can be used to optimize the face-milling cutter in high speed machining.

Face milling is the most common milling operation and can be performed using a wide range of different tools. Tool life is an important indicator of the milling operation in manufacturing process. In high speed machining, there are two forms of security lapse including cutter body rupture and flying out to effect face-milling cutter life. This study investigates the influence of cutting tool body material on the distribution of stress field by utilizing finite element simulations (FEM). Two kind of cutting tool body materials including Al alloys and 40CrMo tool steels were used for simulation. The cutting tool was set to be idling under different rotation speed including 5000r/min, 10000r/min, 15000r/min, 20000r/min and 30000r/min, respectively. Results show that for the two kinds of materials, the security cutting speed is 15000r/min to Al alloys and 20000r/min to 40CrMo tool steels respectively. Under the same cutting condition, 40CrMo tool steels have higher shear stress than that of Al alloys, in hence they have higher security rotation speed.

Swing movable teeth reducer is a new type of small teeth difference planetary gear reducer, which is used to transmit the rotary motion and power between two shafts with same axis. It is important to carry on the systematic design and performance simulation of the reducer and seek the optimization design of the products by the virtual prototyping. Based on the study of the principles and characteristics of the swing movable teeth transmission, this study established the virtual prototype and achieved the dynamical simulation of the reducer by CAD/CAE software. The rotate speed and force analysis proved the feasibility of the model.

In view of application requirements, control axes, the development cycle and other factors of open CNC machine tools, we consider the modular as the guiding ideology and propose a design method of three-dimensional engraving and milling machine based on open CNC system. In this paper we make a detailed design for mechanism structure and control system. Experiments show that this machine has milling and engraving capabilities, can process metal and non-metallic parts, which is a high efficiency, multi-function numerical control equipment.