Int J Adv Manuf Technol
DOI 10.1007/s00170-013-5356-4
ORIGINAL ARTICLE
Failure analysis of support during profile cutting process using
horizontal milling machine
Kadir Gok & Erol Turkes & Suleyman Neseli &
Yasin Kisioglu
Received: 23 April 2013 / Accepted: 26 September 2013
# Springer-Verlag London 2013
Abstract In this study, the effects of cutting forces on the
support of horizontal woodworking milling machine are ex-
amined during profile cutting process using both experimental
and analytical approaches. The support modeled in 3D using
SolidWorks software is a crucial component of the horizontal
milling machine used to locate and fix the wood workpiece
during the cutting process on the workbench. The effects of
cutting forces on the support specimens are measured exper-
imentally considering vibration and failure analyses. Analyt-
ical stresses and modal analyses of the support were also
calculated using finite element-based analysis approach. Chat-
ter vibration forces of the cutting tool which resulted from
cutting forces in x -, y -, and z -directions were calculated
analytically during the profile cutting process. The results
showed that both cutting and chatter forces are highly effec-
tive on the support component failure of the woodworking
milling machines.
K. Gok (*)
Technical Science College, Department of Machine and Metal
Technologies, Dumlupinar University, Kutahya 43100, Turkey
e-mail: kadirgok67@hotmail.com
E. Turkes
Department of Mechanical Engineering, Dumlupinar University,
Tavsanli Yolu 10 Km, Kutahya 43100, Turkey
e-mail: eturkes@dpu.edu.tr
S. Neseli
Technical Science College, Department of Machine and Metal
Technologies, Selcuk University, Konya 42003, Turkey
e-mail: sneseli@selcuk.edu.tr
Y. Kisioglu
Department of Mechanical Education, Kocaeli University,
Umuttepe Campus, Kocaeli 41000, Turkey
e-mail: ykisioglu@kocaeli.edu.tr
Keywords Chatter vibration . Finite element method .
Horizontal milling machine . Support for machining . Failure
analysis
1 Introduction
Horizontal milling machine taken into account in this study is
a woodworking milling machine which is named based on the
cutting tools and workpiece materials. In the milling ma-
chines, profile cutting tool cutting processes are generally
used and performed horizontally so that it is called horizontal
profile milling machines. They work as semi- or full automatic
according to their working conditions and cutting principles,
e.g., workpieces are controlled manually in the semiautomatic
milling machines of which motor and shafts are mounted
under the workbench. Using these machines, many different
types of cutting processes such as grooving, cordon, chamfer,
boss, etc. can be performed easily. In these processes, the
workpieces are located on the workbench and propped up
the support to the cutting forces since these forces are trans-
ferred to the support through workpiece. The support, one of
the most important parts of these machines, is used to provide
stationary or adjusting positions of the workpieces on the
workbench. The cutting tools are producing orthogonal cut-
ting forces along with chatter forces that cause stresses and
deformations on the workpiece and support. These forces are
absorbed by the workpiece and support during the cutting
process.
No available studies in literature about the design failure of
the supports had been done for the woodworking milling
machines, but few studies are appearing about fixture design
and portal tie rod support. Bonjak et al. [1] studied on the
failure analysis of bucket wheel excavator portal tie rod sup-
port using finite element method (FEM) simulations,
Momcilovic et al. [2] worked on the failure of 28-MW

horizontal hydro-turbine shaft based on the failure criteria
using numerical approach, and Bayrakceken et al. [3]
performed fracture failure analysis of a camshaft of an auto-
mobile engine using the FEM approach. There is no specific
study interested in the support failure analysis of the horizon-
tal milling machines for the woodworking process.
In this study, the support of the woodworking horizontal
milling machines subjected to orthogonal cutting and chatter
forces is analyzed using both experimental and numerical
approaches. Experimental studies were carried out using three
support specimens at a small woodworking engineer's work-
shop. The cutting forces are simulated using the finite element
analysis (FEA) method to calculate the stresses which oc-
curred on the support. The modal analysis of the support
subjected to cutting and chatter forces is also performed by a
hammer impact using CutPro 8 software. Obtained results
from both FEA simulations and modal analyses are compared
with corresponding experimental results.
2 Experimental studies
In the experimental studies, a profile woodworking milling
machine, Netmak brand, as seen in Fig. 1 is used. The pro-
cessing parameters were selected from the manufacturer's
catalog for the experiments and these parameters are also
compared to relevant literature [4]. These parameters were
selected as the profile milling motor power of 2.5 kW/h,
spindle speed of 2,890 rpm, feed rate of 10 m/min, cutting
speed of 8.31 m/s, and profile cutter diameter of 55 mm. For
the experiments, oakwood and high-speed steel materials
were selected for the workpiece and cutting tool, respectively.
Fig. 1 Horizontal milling machine
Int J Adv Manuf Technol
2.1 Definition of cutting forces
During the profile cutting process, the cutting forces on the
workpiece occur when the cutting tool plunges. The work-
piece is located in the workbench and the cutting tool is
positioned in the coordinate system of the milling machine
as seen in Fig. 2. These cutting forces are generally defined as
compressive forces applied to the workpiece during the cut-
ting process. As seen from Fig. 2, the normal compression
(P n) and the feeding (P fd) forces are exerted in z- and x-
directions, respectively. The tangential cutting force (P c) is
distributed to effect in both x- and y-directions. The frictional
force (P f) is exerted in x-direction, opposite direction of the
cutting, during the cutting process. The vectoral summation of
these forces can be written as follows:
Pfd Pc P f 1
P f Pn 2
The cutting process is performed with these forces along
with the processing parameters. During the cutting process,
the support of the workpiece failed and was damaged as
shown in Fig. 3. As seen, these experimental studies were
repeated for the three support specimens which were damaged
in the same region of the support.
3 Chatter vibration analysis
Chatter occurs in the machining operations due to interaction
of the tool and workpiece structure during the machining
process. Each tooth pass leaves a modulated surface on the
workpiece due to the vibrations of the tool and workpiece
structures, causing a variation in the expected chip thickness.
Under certain cutting conditions (i.e., feed, depth, and speed),
large chip thickness variations, and hence force and displace-
ment variations, occur and chatter is present. The chatter
vibrations result in poor surface finish, excessive tool wear,
reduced dimensional accuracy, and tool damage. During the
milling process, usually conservative cutting conditions are
selected to avoid chatter vibrations that decrease productivity.
Since extensive experimental study is usually not cost effec-
tive, analysis techniques are used to generate the stability lobe
diagram and plots for the stable and unstable regions in the
cutting processes. Stability lobe diagrams may be used for
process planning for the chatter-free machining operation and
machine tool design. All regenerative chatter analysis tech-
niques are beginning with the models of the machining force
process and toolworkpiece structure. These models are com-
bined to form a closed-loop dynamical model of the machin-
ing operations [5].
The general dynamic force process model of the surface
milling operation is presented in the sense dynamics that affect
Int J Adv Manuf Technol
Fig. 2 Cutting forces on the
workpiece
tool and workpiece vibrations on the instantaneous tooth feed.
The model of the toolworkpiece structure is then presented
and the numerical parameters for a particular toolworkpiece
structure are also given. The stability analysis technique de-
rived by [6] for linear force processes is summarized. Milling
cutters can be considered to have two orthogonal degrees of
freedom (DOF), as shown in Fig. 4, in either metal or wood
cutting process. The cutter is assumed to have a number of
teeth, N , without helix angle. The cutting forces motivate the
structure to move in x- and normal y-directions that cause
dynamic displacements in x - and normal y-directions, respec-
tively [7].
The dynamic displacements are carried out in rotating tooth
number j in the radial or chip thickness direction with the
coordinate transformation of v j =x sin j y cos j , where j g j 1
is the instantaneous angular immersion of tooth j measured
clockwise from the normal y -axis. If the spindle rotates at an
angular speed of (rad/s), the immersion angle varies with
time as j (t)= t. The resulting chip thickness consists of
Fig. 3 Failure regions on the support
static part (s t sin j ), attributed to rigid body motion of cutter,
and a dynamic component caused by the vibrations of the tool
at the present and previous tooth periods. Since the chip
thickness is measured in the radial direction (v j ), the total chip
load, h ( j ), can be expressed as follows:

 


h j st sin j v j;0 v j g j 3
where s t is the feed rate per tooth and (v j,0, v j ) are the dynamic
displacements of the cutter at the previous and present tooth
periods, respectively. The function g( j ) is a unit step func-
tion that determines whether the tooth is in or out of cut that is
in the following conditions:


st < j < ex


g j 0 j < st or j > ex 4
where sts and ex are the start and exit immersion angles of
the cutter to and from the cut, respectively. Henceforth, the
static component of the chip thickness (s t sin j ) is dropped
from the expressions because it does not contribute to the
dynamic chip load regeneration mechanism. Therefore,

  

h j xsin j ycos j g j 5
where x =x x 0 and y =y y 0. Here, (x, y) and (x 0, y 0)
represent the dynamic displacements of the cutter structure at
the present and previous tooth periods, respectively.
The tangential (F tj ) and radial (F rj ) cutting forces acting on
the tooth j can be defined as proportional to the axial depth of
cut (a) and chip thickness (h) as follows:
 Int J Adv Manuf Technol

Fig. 4 Dynamic modeling for 2

DOF profile milling tool

 
F tj K t a h j X

6 At  Ar eirt 11
F rj K r F tj r
Z
1
where K t and K r are the constant cutting coefficients. Ar  At eirt dt
Resolving the cutting forces in x- and y-directions,
0

F xj F tj cos j F rj sin j
7 The number of harmonics (r) of the tooth passing frequency
F yj F tj sin j F rj cos j
() to be considered for an accurate reconstruction of [A(t)]
Summing these forces considering all teeth, the total dynamic depends on the immersion conditions and number of teeth in
milling forces acting on the cutter can be rewritten as follows: cut. In the most simple approximation, the average component
of the Fourier series expansion is considered (i.e., r =0), then
X
N 1  
Fx F xj j 8 Z
1
j0 A0  At dt 12
X
N 1  
0
Fy F yj j
j0
Since [A 0] is valid only between the entry ( st) and exit
where j = +j p and cutter pitch angle is p =2 /N . ( ex) angles of the cutter (i.e., g( j )=1) and the j = t and
Substituting chip thickness (5) and tooth forces (8) into (9)
and rearranging the resulting expressions in matrix form yield
as follows:


Fx 1 a axy x
a K t xx 9
Fy 2 ayx ayy y

where a xx , a xy, a yx , and a yy are time-varying directional milling

force coefficients. Angular position of the parameters is chang-
ing depending on time and angular velocity, then Eq. (9) in time
domain can be defined in a matrix form as follows [8, 9]:
1
f F t g aK t At ft g 10
2
As the cutter rotates, the directional factors vary with time,
which is the fundamental difference between the milling and
operations such as turning where the direction of the force is
constant. However, like the milling forces, [A(t)] is periodic at
tooth passing frequency =N or tooth period =2 /.
Thus, it can be expanded into a Fourier series as follows: Fig. 5 Dynamic cutting model of the cutting tool for jth tooth
Int J Adv Manuf Technol

Fig. 6 The measurement of the

chatter frequency tests

p = , it becomes equal to the average value of [A(t)] at factors must be considered and the resulting stability expres-
cutter pitch angle p =2/N: sion must be solved with numerical iterations [6]. The chatter
predictions are investigated for the orthogonal cutting in the
Zex
 milling process as seen in Fig. 5. Machine chatter vibrations
1 N xy
A0 Ad xx 13 are predicted in orthogonal cutting with 2 DOF milling system
p 2 yx yy
st by analytical form.
The equations of motion of the cutting system in the feed
where the integrated functions are given as follows: direction (x) and (y) were formed as follows:
1 1
xx cos 2 2K r K r sin 2exst xy sin 22 K r cos 2exst
2 2 mxj xt cxj xt k xj xt F rj
1 1
yx sin 2 2 K r cos 2exst yy cos 22K r K r sin 2exst 15
2 2 myj yt cyj yt k yj yt F tj
The average direction factors are dependent on the radial
where m x and m y are the mass, c x and c y are the damping, and
cutting constant (K r ) and the width of cut bound by entry ( st)
k x and k y are the stiffness coefficients of the jth tooth. The
and exit ( ex) angles. The dynamic milling expression in
simultaneous vibrations in the x 1 and x 2 directions are excited
Eq. 10 is reduced as follows:
by the cutting forces F x1 and F x2 , determined by the
1 following expression:
f F t g aK t A0 ft g 14
2
F x1 F x sin 1 F y cos 1
16
where [A 0] is the time-invariant but immersion-dependent F x2 F x sin 2 F y cos 2
directional cutting coefficient matrix. Since the average cut-
ting force per tooth period is independent of the helix angle, where F x and F y are cutting forces obtained by decomposing
[A 0] is valid for helical end mills as well. Fourier coefficient the cutting (radial) force F r and the thrust (tangential) F t
[A 0] may not be sufficient for accurate prediction of chatter into the corresponding direction, given by the following
stability. In such cases, higher harmonics of the directional expression:

F x F r cos F t sin
Table 1 Outputs of the impact hammer and microphone tests for cutting 17
system F y F r sin F t cos

Direction m x,y [kg] f nx,y [Hz] k x,y [N/m] x,y [%] f c [Hz] where is the variation of rake angle 0 or the clearance
6 1 angle . Due to the oscillation of the tool in wave cutting
x 0.352 597.37 4.96410 1.02210 650
y 0.411 621.77 6.266106 1.993102 surface, the rake angle, 0, and the clearance angle, , can
be expressed as follows:
 Int J Adv Manuf Technol

Fig. 7 Experimental setup for

modal parameter measurements


  
y s coss 0
0 0 tan1 Ft a h a h j Kt
v
 18
sinc cosc s 0   
y s sin s 0
0 0 tan1 Fr a h a h j Kr Ft Kr
v sinc cosc s 0
21
where y is the velocity of the tool vibration in the y-direction
and v is the cutting speed. The cutting force, F r, and the thrust where s is the shear stress, s is the average friction angle,
(tangential) force, F t , described in [6, 10] can be reexpressed and c is the shear angle. The radial force F r is assumed to be
as follows: proportional to the tangential force with a ratio of K r =F r /F t =
tan( s 0).
 
F tj K t a h j Rcos0 3.1 Analysis of profile cutting system
19
F rj K r F tj Rsin0
The milling stability analysis, orthogonal cutting model de-
veloped by Koenigsberger and Tlusty [11], is used consider-
where R is the resulting cutting force and defined as follows:
ing the average direction of the cut. But Tlusty and Ismail [12]
showed that the time domain simulations would be required
q

2
2 for an accurate stability prediction in milling process. Sridhar
R F rj F tj 20 et al. [13, 14] performed a comprehensive analysis of milling
stability which involved numerical evaluation of the dynamic
The orthogonal F r and thrust F t forces can also be rewrit- milling system's state transition matrix. Minis et al. [9] and
ten as follows: Minis and Yanushevsky [15] used Floquet's theorem and the

Fig. 8 Real (a) and imaginary

graphics (b) obtained by modal
analysis of the 2-DOF system in
x-direction
Int J Adv Manuf Technol
Fig. 9 Real (a) and imaginary
graphics (b) obtained by modal
analysis of the 2 DOF system in
y-direction
Fourier series for the formulation of the milling stability and
numerically solved it using the Nyquist criterion. Budak [16]
developed a stability method which leads to analytical determi-
nation of stability limits. The method was verified by experimen-
tal and numerical results and demonstrated to be very fast for the
generation of stability lobe diagrams [6, 17, 18]. This method
was also applied to the stability of ball-end milling [19].
3.2 Modal analysis
In this study, the modal analysis of the support is performed
considering the orthogonal cutting process having 2 DOF.
Values of equivalent mass, stiffness coefficient, damping ratio,
and natural frequency of the cutting system are calculated by
the modal analysis. The measurement of the chatter frequency
is performed by a microphone test as shown in Fig. 6 and the
corresponding values are given in Table 1.
The transfer function of the cutting systems is calculated
for the milling machine considering the different spindle
speeds [rotations per minute]. The maximum axial depth of
cut [millimeter] for the chatter vibration-free machining is
obtained from the dynamic cutting tests. When the spindle
speed increases, the values of (a lim) decrease since PDR
decreases as well.
The modal analysis of the cutting system is performed by a
hammer impact using the CutPro 8 software as seen in Fig. 7.
The specific cutting force for the dried oakwood material of
Fig. 10 Graphics of power spectrum for the 2 DOF system
the workpiece is designated as K t =1.510+ 8 N/m2. The
diameter, cutting width, and attach length (L ) of the cutting
tool are taken as 50, 40, and 60 mm, respectively. The number
of cutter teeth with a zero helix angle is taken as 3. The chatter
frequencies (f c [Hz]) given in Table 1 were obtained using
LabView 7.1 software. Experimental modal analysis of cut-
ting system was performed by measuring the transfer func-
tions using hammer, force transducer, and accelerometer at-
tached to the milling machine. The accelerometer used in the
test measures weighs in the range of 50 g with the sensitivity
of 104.3 mV/g considering the resonance frequency of
40.0 kHz, and the hammer impact force ranges from 0 to
500 N with the impulse sensitivity of 10 mV/N.
The equivalent mass m x ,y, stiffness coefficient k x ,y ,
damping ratio B x,y, and natural frequency f nx,y of the support
(see Table 1) are feed in both x- and tangential y-directions,
respectively. The chatter frequency of the cutting system is
designated as f c . The specific cutting force, K [N/m2], for a
stability analysis is the most important criterion for the exper-
imental matrix. According to Porankiewicz et al. [20], it is also
very important to get the proper kind of variable influence for
the incomplete experimental matrices. The choice to use a
simpler model is expected to result in decreased approxima-
tion quality and also reversing the impact of lower importance
variables. It must also be pointed out that the statistical rela-
tionships outside the ranges of independent variables chosen
in the experimental matrix are not valid. For some functions

Fig. 11 Transfer function
diagram of dynamic cutting
system in the x- and y-directions
without interactions, points lying outside an analyzed range of
independent variables are charged by errors in a meaningful
degree that would not have been large enough to affect pre-
dictions made within the range of the data. Any additional
justification for a choice of a certain type of function makes
sense, in authors opinion, if the data exists from additional
experiments carried out under the same machining conditions.
Hence, the specific cutting force, K , can be calculated as
follows:
K c1 eP c8 P c2 F c3 f R c4 bF5 f cR6 c7 of each subsequent cut. The correlation between the specific
22
where b k and c k are k estimators evaluated in statistical
model, F is cutting angle, and f R is feed per revolution
[millimeters per revolution]. The specific cutting force, K , is
used in rather old literature for wood machinability character-
ization; nevertheless, in the present work, it was taken into
account for comparison with the literature. The estimators
were evaluated for dependence between the specific cutting
force K and the cutting angle F and the feed per revolution,
f R , according to formula given in [21]. Hence, the specific
cutting force K decreasingly dropped with increasing rate of
feed per revolution f R and increasingly fell with enlargement
of the cutting angle F. Furthermore, according to Bucar [22],
due to the fact that in the cutting process, the cutting or
exciting force also depends on relative displacements between
the tool and workpiece. The dynamic model has been set up as
nonlinear where the exciting force is merely the consequence
Fig. 12 Real (a) and imaginary
graphics (b) obtained by modal
analysis in x-direction of the
support
Int J Adv Manuf Technol
of the instantaneous cross-sectional area of the chip and spe-
cific cutting force K . If the condition does not meet, the
process of cutting itself is already nonlinear and as such
practically impossible to analyze [21]. From the aspect of
the manner of excitation and response of the structure of the
machining system, the process of periodic circular cutting of
wood tissue usually does not meet the requirements of closed-
loop systems. The system consists of specific periodic forced
excitation and self-excitation which is interacting mutually or
modulating the cutting force to determine the initial conditions
cutting force K and the rotational angle of the tool was
determined experimentally and introduced into the simulation
program in [23]. The only parameter which changed during
simulation of the cutting process was the angle that is
defined between the tool and the workpiece. The changes of
this angle affect the changes in specific cutting force. Addi-
tionally, according to [24], if the average tangential compo-
nent of the cutting force is expressed in the form F t =K t A hm ,
then the specific cutting force can be expressed as follows:
Ft
Kt const: 23
Ahm
where the coefficient A hm represents the influence of the mean
cross-sectional area of the chip. The coefficient of the mean
cross-sectional area of the chip is expressed as a product of
a h cm , and the specific cutting force at a condition of 0<c<1
can be expressed as follows:
Int J Adv Manuf Technol
Table 2 Outputs of the hammer impacts and microphone tests
Direction m xr [kg] f nxr [Hz] k xr [N/m] xr [%] f cr [Hz]
x 2.254 704.6 4.42107 2.343102 650
Ft
Kt
ahcm
The orthogonal cutting process of maple and the modeling of
the cutting mechanics are also presented experimentally to mea-
sure the cutting forces for the different feed rates [23]. A set of
equations relating the tangential and feed forces of the tool edge
width and feed rate (chip thickness) to calculate the chip and edge
cutting force coefficients was developed. The chip and edge
force coefficients were also calculated experimentally to obtain
the cutting forces and plotted in a polar coordinate system with
respect to the fiber orientation of the maple disk. The polar
coordinate system which represents the cutting forces and cutting
force coefficients provides an excellent visual relation between
the cutting forces and wood fiber orientation.
Time response of the accelerator was measured by the
frequency and transformed into data frequency domain for
cutting tool. For the transformation of the time data, fast
Fourier transform method was utilized. The collected data
using CutPro MalTF software are used for the modal anal-
ysis to calculate modal parameters. Real and imaginary
graphics of the transfer function of the system in the feed x-
and tangential y-directions are obtained as given in Figs. 8 and
9, respectively. The modal parameter values are given in
Table 1. As seen, the cutting test for 2 DOF system was
performed without cooling fluid conditions.
The cutting test data were processed employing LabVIEV
7 software. Noise produced by a hammer during this process
is recorded by a microphone attached to power supply. Noise
data was recorded for the time domain via LabVIEV 7 soft-
ware as seen in Fig. 8. This data is transformed into frequency
domain, and then, the spectrum graphic is formed. The
Fig. 13 Graphics of power spectrum for the SDOF system
24
Fig. 14 Transfer function of the support in x-direction
frequency that corresponds to the highest amplitude in the
spectrum graphic can be determined as a chatter frequency of
the cutting tool. The chatter frequencies are determined about
650 Hz. The dominant mode in the cutting system with 2 DOF
found is about 650 Hz as given in Fig. 10. The rest modes are
created by the rest components of the milling machine tool.
Based on the modal analysis, the transfer function diagram
of dynamic cutting system with the length of cutting tool, L =
60 mm, in the feed x - and tangential y-directions is given in
Fig. 11. As seen, the first mode is the dominant mode of
cutting system.
Chatter vibration of the cutting system is moved to the
support of the machine tool in the feed x -direction by the
workpiece during the cutting process. Bearings of the support
are always broken from the same region by the chatter vibra-
tions. Hence, the modal analysis of the support is performed in
the feed x -direction. Real and imaginary graphics of the
transfer function of the support in the feed x-direction are
obtained as given in Fig. 12, and the modal parameters are
given in Table 2.
The support of machine tool is bearing to the driving rod
and sliding plate within adjustable angle. The diameter,
30 mm, and length, 200 mm, of the driving rod are given
initially. In Table 2, m xr, k xr, B xr, and f nxr are designated as the
equivalent mass, stiffness coefficient, damping ratio, and nat-
ural frequency of the support in the feed x -direction,

Fig. 15 Stability lobe diagram
respectively. As seen in the table, f cr is the chatter frequency
of the support. This system has a single degree of freedom
(SDOF).
The frequency, f cr , of the cutting system based on the
highest amplitude in the spectrum graphic can be determined
as the current chatter frequency of the tool. The chatter fre-
quency obtained is about 650 Hz. The dominant mode in
cutting system with SDOF obtained is about 650 Hz as seen
in Fig. 13. The rest modes are created by the rest components
of the milling machine tool.
From the modal analysis results of the attached length of
the driving rod of L =200 mm used in the feed x-direction, the
transfer function of the support is obtained as given in Fig. 14.
As seen, the first mode is the dominant mode of the support.
Stability lobe is calculated from the chatter analysis to prevent
the axial depth of cut and spindle speed as seen in Fig. 15.
Fig. 16 Mesh generation of the horizontal milling machine
Int J Adv Manuf Technol
Fig. 17 Failure regions of the support
4 Computer-aided finite element analysis
A commercial finite element-based software, ANSYS work-
bench, is employed to predict the failure of the support during
the cutting process. In the finite element modeling process,
interaction between the workpiece and cutting tool is simulat-
ed. The cutting forces exerted by the cutting tool are applied to
the workpiece which is resisted by the support. The modeling
of the workpiece, support, cutting tool, and workbench are
performed in 3D using SolidWorks program. These models
are imported into ANSYS to prepare the finite element model.
4.1 Loading and boundary conditions
The 3D models are imported into ANSYS workbench and the
mesh generation of the FEA model is created. The mesh
generation of the models is created using hexagonal element
type as seen in Fig. 16. The support is fixed from the hole and
the cutting forces are applied to the workpiece (see Fig. 2).
Contact definitions among the workpiece, support, and work-
bench are defined as a bounded contact. Additionally, fric-
tional contact is defined between the workpiece and work-
bench with a frictional coefficient of 0.35. The generated FEA
model has 25,171 nodes and 11,210 elements.
4.2 Stress distribution of the support
The stress distributions of the support are calculated
employing the finite element-based simulation using the linear
elastic material conditions. The moduli of elasticities for the
oakwood workpiece and cutting tool are selected as 11 and
210 GPa, respectively, from the ANSYS material library. The
support is made out of gray cast iron with a modulus of
elasticity of 11 GPa and Poisson's ratios of 0.28 which were
selected from the ANSYS material library.
From the simulations, the maximum equivalent stresses are
obtained around the bearing places of the support as seen in
Int J Adv Manuf Technol
Fig. 17. The maximum equivalent stress obtained is about
1.897 MPa which is lower than the ultimate tensile strength of
the cast iron, 240 MPa. In addition, the normal stresses at the
damaged region are also calculated in the x- and y -directions.
The normal stresses ( x ) and ( y ) occurred in x - and y -
directions are obtained about 0.789 and 0.486 MPa,
respectively.
5 Conclusions
In this study, the failure reasons of the support component of
the woodworking horizontal milling machine broken consis-
tently at the same place during the profile cutting process are
examined using experimental and analytical studies. One of
the biggest issues for the failing of the support is the dynamic
cutting loads generated by the orthogonal cutting forces.
Three support specimens were used in the experimental stud-
ies and it was observed that the supports failed in the same
place (see Figs. 3 and 17). Because of dynamic cutting forces,
the chatter vibration analysis of the profile cutting tool has
been done to determine the cutting conditions. The structural
modal analysis was performed to obtain the natural frequency,
absorption rate, constant of rigidity, and equivalent mass (see
Figs. 8, 9, 10, 11, and 12). The stress analysis of the support
subjected to orthogonal cutting forces was also completed
using the FEA-based modeling to obtain the highest stress
concentrations and equivalent stresses (see Fig. 17).
Based on the results, the intensive natural frequencies,
maximum equivalent stresses, and stress concentrations in
the failed regions were calculated employing the modal and
finite element-based analyses, respectively. Therefore, the
failure of the support is produced by the chatter vibrations
due to the dynamic cutting loads and stress concentrations
since the geometry of the support is not feasible. In order to
eliminate the failure of the support is to use the redesign of the
support and the processing parameters should be selected
considering the stability lobe diagrams (see Fig. 15). Based
on the results, the geometry of the support for the woodwork-
ing horizontal milling machines should be redesigned. In
order to redesign, the thickness of the support part should be
increased. Another alternative solution for the support part is
to select the more suitable material having higher fracture
toughness since the fracture toughness of the cast iron is so
weak to resist the cyclic loads.
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