New Approach to High-Speed Multi-Coordinate Milling Based on Kinematic Cutting Parameters and Acoustic Signals

In this work, a new approach to high-speed multi-coordinate milling was developed. The new approach is based on a new model of trochoidal machining; this is, in turn, based on the theoretical thickness of a chip and its ratio to the cutting edge’s radius, allowing us to establish the vibroacoustic indicators of cutting efficiency. The new model can be used for the real-time assessment of prevailing cutting mechanisms and chip formation. A set of new indicators and parameters for trochoidal high-speed milling (HSM), which can be used to calculate tool paths during technological preparation of slotting, was determined and verified. The size effect in the multi-coordinate HSM of slots on cast iron was identified based on the dependency of vibroacoustic signals on the cutting tooth’s geometry, HSM’a operational machining modes, theoretical chip thicknesses, the sizes of the cut chips, and the quality/roughness of the surface being machined. Based on the analysis of vibroacoustic signals, a set of the most important indicators for monitoring HSM and determining cutting and crack-formation mechanisms during chip deformation was derived. Based on the new model, recommendations for monitoring HSM and for assigning the tool path relative to the workpiece during production preparation were developed and validated.