Modeling and Prediction of Cutting Noise in the Face-Milling Process

A cutting noise prediction model is developed to relate the cutter-workpiece vibrations to the sound pressure field around the cutter in the high-speed face-milling process. The cutter-workpiece vibration data are obtained from a dynamic mechanistic face-milling force simulation model. The total noise predicted, based on both cutting noise and aerodynamic noise prediction, compares well to the noise observed experimentally in the face-milling process. Using the model, the effects of various machining and cutter geometry parameters are studied. It is shown that cutter geometry, machine dynamics, and cutting speed all play important roles in determining overall noise in face milling.