Modeling the Chip-Work Contact Force for Chip Breaking in Orthogonal Machining With a Flat-Faced Tool

1998 ◽  
Vol 120 (1) ◽  
pp. 49-56 ◽  
Author(s):  
B. K. Ganapathy ◽  
I. S. Jawahir
Keyword(s):  
Cutting Force ◽  
Contact Force ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Force Model ◽  
Two Dimensional ◽  
Cutting Force Model ◽  
Chip Breaking ◽  
Orthogonal Machining

The present tendency towards increased automation of metal cutting operations has resulted in a need to develop a model for the chip breaking process. Conventional cutting force models do not have any provision for the study of chip breaking since they assume a continuous mode of chip formation, where the contact action of the free-end of the chip is ignored in all analyses. The new cutting force model proposed in this work incorporates the contact force developed due to the free-end of the chip touching the workpiece, and is applicable to the study of two-dimensional chip breaking in orthogonal machining. Orthogonal cutting tests were performed to obtain two-dimensional chip breaking. The experimentally measured cutting forces show a good correlation with the estimated cutting forces using the model. Results show that the forces acting on the chip vary within a chip breaking cycle and help identify the chip breaking event.

Analysis of Cutting Forces in Precision Turning Based on Oblique Cutting Model

2010 ◽  
Vol 97-101 ◽  
pp. 1961-1964 ◽  
Author(s):  
Wei Guo Wu ◽  
Gui Cheng Wang ◽  
Chun Gen Shen
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Differential Method ◽  
Force Model ◽  
Cutting Force Model ◽  
Linear Change ◽  
Oblique Cutting ◽  
Precision Turning ◽  
Cutting Model

In this work, the prediction and analysis of cutting forces in precision turning operations is presented. The model of cutting forces is based on the oblique cutting force model which was rebuilt by two coordinate conversions from the orthogonal cutting model. Then the cutting field in precision turning was divided into two fields which are characterized as curve change and linear change on cutter edge and they were modeled respectively. Cutting field of cutter nose was modeled by differential method and its cutting force distribution is predicted by the proposed method. The predicted results for the cutting forces are in agreement with the experimental results under a variety of operation variables, including changes in the depths of cut and in the feedrate.

Mechanistic Cutting Process Calibration via Microstructure-Level Finite Element Simulation Model

2004 ◽  
Vol 126 (4) ◽  
pp. 706-709 ◽  
Author(s):  
Sunghyuk Park ◽  
S. G. Kapoor ◽  
R. E. DeVor
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Cutting Forces ◽  
Model Calibration ◽  
Gray Iron ◽  
Carbon Steels ◽  
Cutting Process ◽  
Force Model ◽  
Cutting Force Model ◽  
Orthogonal Machining

A methodology for mechanistic cutting force model calibration via microstructure-level finite element cutting process simulation is presented and applied to ferrous materials, including ductile and gray irons and carbon steels. The methodology combines graphite, ferrite, and pearlite grains to produce ductile iron, gray iron, and carbon steel microstructures and obtains cutting forces via orthogonal machining simulations. The simulated forces are used to perform the cutting force model calibration. The cutting forces for the turning process are predicted based on the calibration thusly obtained and experimentally shown to be in good agreement with actual cutting force data.

Analytical cutting force modelling of micro-slot grinding considering tool-workpiece interactions on both primary and secondary tool surfaces

2021 ◽  
pp. 1-43
Author(s):  
Ashwani Pratap ◽  
Karali Patra
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Surface Interactions ◽  
Surface Interaction ◽  
Edge Density ◽  
Force Model ◽  
Height Distribution ◽  
Force Modeling ◽  
Tool Surface

Abstract This work presents an analytical cutting force modeling for micro-slot grinding. Contribution of the work lies in the consideration of both primary and secondary tool surface interactions with the work surface as compared to the previous works where only primary tool surface interaction was considered during cutting force modeling. Tool secondary surface interaction with workpiece is divided into two parts: cutting/ ploughing by abrasive grits present in exterior margin of the secondary tool surface and sliding/adhesion by abrasive grits in the inner margins of the secondary tool surface. Orthogonal cutting force model and indentation based fracture model is considered for cutting by both the abrasives of primary tool surface and the abrasives of exterior margin on the secondary surface. Asperity level sliding and adhesion model is adopted to solve the interaction between the workpiece and the interior margin abrasives of secondary tool surface. Experimental measurement of polycrystalline diamond tool surface topography is carried out and surface data is processed with image processing tools to determine the tool surface statistics viz., cutting edge density, grit height distribution and abrasive grit geometrical measures. Micro-slot grinding experiments are carried out on BK7 glass at varying feed rate and axial depths of cut to validate the simulated cutting forces. Simulated cutting forces considering both primary and secondary tool surface interactions are found to be much closer to the experimental cutting forces as compared to the simulated cutting forces considering only primary tool surface interaction.

Analysis of Cutting Force in Elastomer End-Milling

2017 ◽  
Vol 11 (6) ◽  
pp. 958-963
Author(s):  
Koji Teramoto ◽  
◽  
Takahiro Kunishima ◽  
Hiroki Matsumoto
Keyword(s):  
Parameter Identification ◽  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Process Models ◽  
Force Model ◽  
Cutting Force Model ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
The Stability

Elastomer end-milling is attracting attention for its role in the small-lot production of elastomeric parts. In order to apply end-milling to the production of elastomeric parts, it is important that the workpiece be held stably to avoid deformation. To evaluate the stability of workholding, it is necessary to predict cutting forces in elastomer end-milling. Cutting force prediction for metal workpiece end-milling has been investigated for many years, and many process models for end-milling have been proposed. However, the applicability of these models to elastomer end-milling has not been discussed. In this paper, the characteristics of the cutting force in elastomer end-milling are evaluated experimentally. A standard cutting force model and its parameter identification method are introduced. By using this cutting force model, measured cutting forces are compared against the calculated results. The comparison makes it clear that the standard cutting force model for metal end-milling can be applied to down milling for a rough evaluation.

Improved dynamic cutting force modelling in micro milling of metal matrix composites part II: Experimental validation and prediction

2019 ◽  
Vol 234 (8) ◽  
pp. 1500-1515
Author(s):  
Zhichao Niu ◽  
Kai Cheng
Keyword(s):  
Cutting Force ◽  
Metal Matrix Composites ◽  
Cutting Forces ◽  
Metal Matrix ◽  
Micro Milling ◽  
Force Model ◽  
Matrix Composites ◽  
Cutting Force Model ◽  
Side Milling ◽  
Dynamic Cutting Force

The effects of cutting dynamics and the particles' size and density cannot be ignored in micro milling of metal matrix composites. This article presents the improved dynamic cutting force modelling for micro milling of metal matrix composites based on the previous analytical model. This comprehensive improved cutting force model, taking the influence of the tool run-out, actual chip thickness and resultant tool tip trajectory into account, is evaluated and validated through well-designed machining trials. A series of side milling experiments using straight flutes polycrystalline diamond end mills are carried out on the metal matrix composite workpiece under various cutting conditions. Subsequently, the measured cutting forces are compensated by a Kalman filter to achieve the accurate cutting forces. These are further compared with the predicted cutting forces to validate the proposed dynamic cutting force model. The experimental results indicate that the predicted and measured cutting forces in micro milling of metal matrix composites are in good agreement.

Accurate Milling Process Simulation Using ME Z-Map Model

Manufacturing ◽  
2003 ◽  
Author(s):  
Han Ul Lee ◽  
Dong-Woo Cho
Keyword(s):  
Cutting Force ◽  
Process Simulation ◽  
Cutting Forces ◽  
Computing Time ◽  
Milling Process ◽  
Simulation System ◽  
Grid Size ◽  
Force Model ◽  
Cutting Force Model ◽  
Edge Node

In this paper, a milling process simulation system was constructed and ME Z-map (Moving Edge node Z-map) model was developed to elevate the performance of this system. The milling process simulation system computes the cutting configuration and then the cutting forces are predicted using these calculated configurations. In this system, an improved cutting force model which is independent of cutting conditions is used to more precisely predict the cutting forces. In the process, the ME Z-map model was used for more accurate computing of cutting configuration. Due to the edge node, ME Z-map model produces more accurate cutting configuration than the conventional Z-map models even with five to ten times larger grid size, which reduces the computing time dramatically. The superiority of the ME Z-map model was confirmed through comparison with the conventional Z-map.

Cutting Force Prediction for Generalized Cornering Milling Process

2011 ◽  
Vol 188 ◽  
pp. 404-409 ◽  
Author(s):  
Xue Yan ◽  
Hua Tao ◽  
D.H. Zhang ◽  
B.H. Wu
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Milling Process ◽  
Force Model ◽  
Cutting Force Model ◽  
Cutting Force Prediction ◽  
Geometric Relationship ◽  
The Mathematical Model ◽  
Good Agreement

A developed method to predict the cutting forces in end milling of generalized corners is proposed in this paper. The cornering milling process is divided into a series of cutting segments with different cutting states. The mathematical model of the geometric relationship between cutter and the corner profile is established for each segment. Cutting forces is predicted by introducing the classical cutting force model. The computational results of cutting forces are in good agreement with experimental data.

scholarly journals Cutting Force Modeling and Optimization in 3D Plane Surface Machining

1999 ◽  
Author(s):  
Hsi-Yung (Steve) Feng ◽  
Ning Su
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Plane Surface ◽  
Mechanistic Modeling ◽  
Surface Finishing ◽  
Force Model ◽  
Cutting Force Model ◽  
Ball End Milling ◽  
Finishing Machining

Abstract The prediction and optimization of cutting forces in the finishing machining of 3D plane surfaces using ball-end milling are presented in this paper. The cutting force model is developed based on the mechanistic modeling approach. This improved model is able to accurately predict the cutting forces for non-horizontal and cross-feed cutter movements typical in 3D finishing ball-end milling. Optimization of the cutting forces is used to determine both the tool path and the maximum feed rate in 3D plane surface finishing machining. The objective is to achieve highest machining efficiency and to ensure product quality. Experimental results have shown that the cutting force model gives excellent predictions of cutting forces in 3D finishing ball-end milling. The feasibility of the integrated process planning method has been demonstrated through the establishment of optimized process plans for the finishing machining of 3D plane surfaces.

Force Modeling in Laser-Assisted Microgrooving Including the Effect of Machine Deflection

2009 ◽  
Vol 131 (1) ◽  
Author(s):  
Ramesh Singh ◽  
Shreyes N. Melkote
Keyword(s):  
Flow Stress ◽  
Cutting Force ◽  
Cutting Forces ◽  
Laser Power ◽  
Continuous Wave ◽  
Dimensional Accuracy ◽  
Thermal Softening ◽  
Depth Of Cut ◽  
Force Model ◽  
Cutting Force Model

Laser assisted mechanical micromachining is a process that utilizes highly localized thermal softening of the material by continuous wave laser irradiation applied simultaneously and directly in front of a miniature cutting tool in order to produce micron scale three-dimensional features in difficult-to-machine materials. The hybrid process is characterized by lower cutting forces and deflections, fewer tool failures, and potentially higher material removal rates. The desktop-sized machine used to implement this process has a finite stiffness and deflects under the influence of the cutting forces. The deflections can be of the same order of magnitude as the depth of cut in some cases, thereby having a negative effect on the dimensional accuracy of the micromachined feature. As a result, selection of the laser and cutting parameters that yield the desired reduction in cutting forces and deflection, and consequently an improvement in dimensional accuracy, requires a reliable cutting force model. This paper describes a cutting force model for the laser-assisted microgrooving process. The model accounts for the effect of elastic deflection of the machine X-Y stages on the forces and accuracy of the micromachined feature. The model combines an existing slip-line field based force model with a finite element based thermal model of laser heating and a constitutive material flow stress model to account for thermal softening. Experiments are carried out on H-13 steel (42 HRC (hardness measured on the Rockwell ‘C’ scale)) to validate the force model. The effects of process parameters, such as laser power and cutting speed, on the forces are also analyzed. The model captures the effect of thermal softening and indicates a 66% reduction in the shear flow stress at 35 W laser power. The cutting force and depth of cut prediction errors are less than 20% and 10%, respectively, for most of the cases examined.

Analysis of Oblique Cutting Forces

1967 ◽  
Vol 89 (2) ◽  
pp. 347-355 ◽  
Author(s):  
Russell F. Henke
Keyword(s):  
Steady State ◽  
Cutting Force ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Single Point ◽  
Orthogonal Cutting ◽  
Cutting Process ◽  
Chip Area ◽  
Oblique Cutting ◽  
The Stability

This paper is the latest of a continuing series on the subject of self-excited machine tool chatter. The representation of the metal cutting process as required by the previously developed closed-loop chatter theory is extended to oblique cutting with tools of practical shape and geometry. The cutting process parameters essential to proper application of the stability theory are found by an analytical formulation leading to a classical eigenvalue problem. Techniques are developed to determine the steady-state constant of proportionality between resultant cutting force and uncut chip area, the direction of resultant cutting force, and the direction of maximum cutting stiffness for any single-point cutting operation. In the process, a general method to predict steady-state oblique cutting forces is evolved. The method depends on certain experimentally justifiable assumptions and utilizes previously compiled orthogonal cutting data.

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