Abstract
This paper proposes a measuring system with visualization based on the high-speed CCD camera for monitoring the behavior of the small-diameter end mill during high-speed milling, in which the characteristics of projection image of the end mills with small-diameter were investigated experimentally. The measurement of an elliptical bar used in stead of an end mill showed that the response delay of the measuring system was very important to affect the image shape, especially in the high speed rotation of the end mill. Also it can be seen that the fluctuation in the system delay disturbs the size and the contour of the end mill in the images, which is characterized by normal distribution. Therefore, the fluctuation is removed by average processing, and the contour or the center of the end mill can be measured precisely.
Further, in order to characterize the cutter behavior from image processing, trials were made on the deflection of the end mill against the static load. When ideas of the equivalent diameter and the length of the end mill are introduced in this analysis, it is shown that the cutter deflection can be related to the static force applied at a cutting edge. As a result, by means of the analysis of the static compliance in the axial direction, the geometrical moment of inertia of the cutting edge part can be sufficiently estimated. And discussion is carried out on the feasibility of the technique for the practical application in monitoring the small-diameter cutting behavior during the high-speed milling process.
