Vibrations and Surface Generation in Slab Milling

In slab milling the quality of the machined surface is directly influenced by the dynamic behaviour of the machine tool. In addition to the cycloidical microgrooves, the dynamic relative motion between the workpiece and tool is superimposed on the machined surface. In general these vibrations cannot be directly identified by investigating the machined surface. By the application of a special purpose milling cutter, microgrooves are generated which are identifiable and from which the relative motions in the cutting zone can be determined by surface topography measurement. It is shown how the groove structure is produced as a function of the kinematics of the process and the relative motions in the zone of cutting. An example based on experimental investigation is used to illustrate the procedure used to determine these relative motions based on analysis of the workpiece surface.