Influence of the machine tool stability and errors on surface quality

In machining of parts, surface quality is one of the most specified customer requirements. Higher precision of manufactured parts and surfaces, reduction of processing time with a simultaneous increase in tool life, and fully automated production are the major aims of research and development in the field of cutting. In order to fulfill these high demands and in addition to ensure high process reliability, new methods for theoretical investigations are required. A phenomenon similar to the formation of chips is the formation of burrs. Burrs are undesirable because they present a hazard in handling machined parts and can interfere with subsequent assembly operations. There are many parameters such as cutting speed, feed rate, and tool nose radius that are known to have a large impact on surface quality. However, there are many more parameters that have an effect on the surface quality (including burrs), but those effects have not been adequately quantified. In order for manufacturers to maximize their gains from utilizing burr-free-manufacturing, an accurate model must be constructed of the machine system, including machine tool stability, chip formation and cutting tool stability. The objective of this paper is to present strategies to increase the surface quality, reduce or prevent burrs on products throughout the product development and manufacturing chain. We also show preliminary results on the effect of machine tool parameters and errors cutting parameters on chip- and burr size and morphology when machining cast aluminum silicon alloy, in an attempt to control chips for easier removal.