A Digital Robust Controller for Cutting Force Control in the End Milling Process

1997 ◽  
Vol 119 (2) ◽  
pp. 146-152 ◽  
Author(s):  
S. J. Rober ◽  
Y. C. Shin ◽  
O. D. I. Nwokah
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Parametric Uncertainty ◽  
Cutting Parameters ◽  
Discrete Systems ◽  
Milling Process ◽  
Robust Controller ◽  
Transform Method ◽  
Constant Cutting Force ◽  
End Milling Process

In this work, a digital robust controller is designed via Quantitative Feedback Theory (QFT) to maintain a constant cutting force in the presence of parametric uncertainty for a time varying end milling process. The QFT controller is designed using the delta transform method for discrete systems. The controller is designed to limit the overshoot and settling time of the cutting force levels over a range of cutting parameters. Models are presented for the cutting process and machine dynamics including parametric uncertainty, and these models are used to develop a controller which meets given tracking and regulation specifications for all plant values. Experimental results are obtained by implementing the controller on a milling machine.

Investigation of Dry Cutting and Applications of Cutting Fluid in Ball-End Milling Process

2011 ◽  
Vol 291-294 ◽  
pp. 3013-3023 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Channarong Rungruang
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
End Milling ◽  
Cutting Parameters ◽  
Milling Process ◽  
Cutting Fluid ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Ball End Milling ◽  
End Milling Process

In order to realize the environmental hazard, this paper presents the investigation of the machinability of ball-end milling process with the dry cutting, the wet cutting, and the mist cutting for aluminum. The relations of the surface roughness, the cutting force, and the cutting parameters are examined based on the experimental results by using the Response Surface Analysis with the Box-Behnken design. The in-process cutting force is monitored to analyze the relations of the surface roughness and the cutting parameters. The proper cutting condition can be determined easily referring to the minimum use of cutting fluid, and the minimum surface roughness and cutting force of the surface plot. The effectiveness of the obtained surface roughness and cutting force models have been proved by utilizing the analysis of variance at 95% confident level.

Intelligent Monitoring and Prediction of Surface Roughness in Ball-End Milling Process

2011 ◽  
Vol 121-126 ◽  
pp. 2059-2063 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Angsumalin Senjuntichai
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Prediction Accuracy ◽  
End Milling ◽  
Milling Process ◽  
Ball End Milling ◽  
Roughness Model ◽  
Force Ratio ◽  
Tool Diameter ◽  
End Milling Process

In order to realize the intelligent machines, the practical model is proposed to predict the in-process surface roughness during the ball-end milling process by utilizing the cutting force ratio. The ratio of cutting force is proposed to be generalized and non-scaled to estimate the surface roughness regardless of the cutting conditions. The proposed in-process surface roughness model is developed based on the experimentally obtained data by employing the exponential function with five factors of the spindle speed, the feed rate, the tool diameter, the depth of cut, and the cutting force ratio. The prediction accuracy and the prediction interval of the in-process surface roughness model at 95% confident level are calculated and proposed to predict the distribution of individually predicted points in which the in-process predicted surface roughness will fall. All those parameters have their own characteristics to the arithmetic surface roughness and the surface roughness. It is proved by the cutting tests that the proposed and developed in-process surface roughness model can be used to predict the in-process surface roughness by utilizing the cutting force ratio with the highly acceptable prediction accuracy.

Dynamic cutting force prediction for micro end milling considering tool vibrations and run-out

2018 ◽  
Vol 233 (7) ◽  
pp. 2248-2261 ◽  
Author(s):  
Xuewei Zhang ◽  
Tianbiao Yu ◽  
Wanshan Wang
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Chip Thickness ◽  
Milling Process ◽  
Force Model ◽  
Dynamic Cutting Force ◽  
Micro End Milling ◽  
Tool Vibrations ◽  
End Milling Process

An accurate prediction of cutting forces in the micro end milling, which is affected by many factors, is the basis for increasing the machining productivity and selecting optimal cutting parameters. This paper develops a dynamic cutting force model in the micro end milling taking into account tool vibrations and run-out. The influence of tool run-out is integrated with the trochoidal trajectory of tooth and the size effect of cutting edge radius into the static undeformed chip thickness. Meanwhile, the real-time tool vibrations are obtained from differential motion equations with the measured modal parameters, in which the process damping effect is superposed as feedback on the undeformed chip thickness. The proposed dynamic cutting force model has been experimentally validated in the micro end milling process of the Al6061 workpiece. The tool run-out parameters and cutting forces coefficients can be identified on the basis of the measured cutting forces. Compared with the traditional model without tool vibrations and run-out, the predicted and measured cutting forces in the micro end milling process show closer agreement when considering tool vibrations and run-out.

Optimization of Process Parameters for Cutting Force for Aluminium 7010 in CNC End Milling Process

2018 ◽  
Vol 10 (6) ◽  
Author(s):  
M. Kishanth ◽  
P. Rajkamal ◽  
D. Karthikeyan ◽  
K. Anand
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Process Parameters ◽  
End Milling ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Optimization Of Process Parameters ◽  
Cnc End Milling ◽  
End Milling Process

In this paper CNC end milling process have been optimized in cutting force and surface roughness based on the three process parameters (i.e.) speed, feed rate and depth of cut. Since the end milling process is used for abrading the wear caused is very high, in order to reduce the wear caused by high cutting force and to decrease the surface roughness, the optimization is much needed for this process. Especially for materials like aluminium 7010, this kind of study is important for further improvement in machining process and also it will improve the stability of the machine.

scholarly journals Cutting force prediction for circular end milling process

2013 ◽  
Vol 26 (4) ◽  
pp. 1057-1063 ◽  
Author(s):  
Baohai Wu ◽  
Xue Yan ◽  
Ming Luo ◽  
Ge Gao
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Milling Process ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
End Milling Process

Selection of Minimum Quantity Lubrication (MQL) Parameters in Milling of Ti-6Al-4V

2012 ◽  
Vol 426 ◽  
pp. 139-142 ◽  
Author(s):  
Zhi Qiang Liu ◽  
X.J. Cai ◽  
Ming Chen ◽  
Qing Long An
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Cutting Temperature ◽  
Minimum Quantity Lubrication ◽  
Milling Process ◽  
Minimum Quantity ◽  
Nozzle Position ◽  
Mql System ◽  
End Milling Process ◽  
Selection Of

Different parameters of Minimum Quantity Lubrication (MQL) system, including air pressure, oil quantity, nozzle position, might have different influences on the cutting force and the cutting temperature. This paper presents an experiment of end-milling titanium alloy with MQL system. The objective of the experiment is to investigate the influences of MQL parameters in milling of Ti-6Al-4V. The results of experiment show that there are different effects on the cutting force and the cutting temperature with different MQL parameters, which will help to select different parameters in the end-milling process of Ti-6Al-4V.

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