Investigation of Cutting Characteristics in Side-milling a Multi-thread Worm Shaft on Automatic Lathe

This paper investigates the cutting characteristics of side-milling which is proposed as a more efficient way to manufacture worms of higher accuracy than form-threading and planetary milling. A tool-tip trajectory based on the tool-workpiece interaction is modelled in terms of matrix transformation. Chip thickness, cutting force and surface roughness are simulated using the calculated tool-tip trajectories. The effects of various errors in the real cutting such as run-out errors of a tool axis, tool setup errors and workpiece deflection due to cutting forces are investigated. The simulation results are verified through numerous experiments on an automatic lathe.