Experimental Study of Ball Milling Process Dynamics by Means of Vibroacoustic Monitoring

This article discusses methods for free-form surface quality and the amplitude parameters of roughness, based on research and field experiments to control the condition of the tool. The methods of correlation analysis, comparison and generalization of the results were used. Data were calculated for different angles of inclination of the tool, taking into account the instantaneous cutting forces and recorded in a range of variable values of the angle of inclination of the surface. The vibroacoustic diagnostic and theoretical data of the presented models at various angles of inclination of the instrument were experimentally verified. As a result, these methods can be used to predict surface roughness parameters when using a ball-end mill. The optimal range of angles for the inclination of the surface treatment tool has been determined, at which minimum values of amplitude roughness are achieved. Empirically obtained, sound vibrations presented in spectral and waveform forms are in good agreement with data from other sources, allowing us to conclude that it is possible to predict roughness parameters and monitor the condition of the cutting edges in real time through acoustic methods. Amplitude parameters decrease with an increase in angle from 10 to 40 degrees. The interrelationships between force analysis and processing directions confirm the use of vibroacoustic diagnostics to predict surface roughness. Vibroacoustic diagnostics, regardless of the location of technological equipment, allows for quick setup of sound devices and evaluation of the effect of cutting modes on roughness parameters.