Estimation of Eccentric Distance for Four-Tooth End Mills Based on Amplitude Spectrum

Time-domain expressions of nominal component and eccentric component that composing horizontal peripheral milling force are derived from geometry of down milling, they are periodic functions with fundamental frequencies same as tooth-frequency and spindle-frequency respectively. By expanding these two time-domain expressions with Taylor series, the frequency-domain description of periheral milling force is obtained. Further mathematical reasoning is exerted on this frequency-domain description, and it proved that as for four-tooth end mills, even-order harmonics of eccentric milling force do not exist, and the amplitude of spindle-frequency component be linear with eccentric distance, but irrelevant with eccentric angle. Above research results imply that the tooth-frequency component of four-tooth end mills is irrelevant with eccentricity, and that eccentric distance can be estimated with amplitudes of tooth-frequency and spindle-frequency components. Results of milling experiment imply that this eccentric-distance estimating method be effective. Spectral characteristics of eccentric milling force for four-tooth end mills are revealed with theory deduction, and the estimation algorithm for eccentric distance with simple calculation is present. Study conclusions can be used in eccentric-geometry estimating and in milling-force modeling.