An Analytic Mechanistic Cutting Force Model for Milling Operations: A Theory and Methodology

1994 ◽  
Vol 116 (3) ◽  
pp. 324-330 ◽  
Author(s):  
A. E. Bayoumi ◽  
G. Yucesan ◽  
L. A. Kendall
Keyword(s):  
Rotation Angle ◽  
Normal Pressure ◽  
Force Model ◽  
Cutting Force Model ◽  
Process Data ◽  
Chip Flow ◽  
Milling Operations ◽  
Cutter Forces ◽  
Chip Removal

An analytic mechanistic force model has been developed to simulate the cutting forces in milling operations. Steps taken to develop the model consisted of cutter surface representation, chip removal kinematics, cutter force definition, and determination of the integration limits from the force equations. The cutter surface is represented by ruled surfaces that are a function of cutter geometry. Cutter forces are determined by integrating the pressure and friction loads acting on these cutter surfaces. The integration limits that are functions of the rotation angle are established. Several techniques dealing with the process parameters are discussed. The model uses process dependent parameters representing normal pressure, chip flow friction, and chip flow kinematics. The paper discusses how process data can be used to establish values for the parameters.

On Study of Cutting Forces Generated by Minor Cutting Edges

2006 ◽  
Vol 532-533 ◽  
pp. 484-487
Author(s):  
Wen Hong Zhao ◽  
Si Chang Xiong ◽  
Dong Hui Wen ◽  
Xun Lv ◽  
Ju Long Yuan
Keyword(s):  
Cutting Forces ◽  
Bearing Steel ◽  
Force Model ◽  
Cutting Force Model ◽  
Flow Angle ◽  
Hard Part ◽  
Experimental Procedure ◽  
Chip Flow ◽  
Gcr15 Bearing Steel ◽  
Force Components

An experimental procedure was developed to separated the uncertain cutting forces generated by the minor cutting edges for interpreted the force components generated by the main and minor cutting edge. Cutting forces generated by minor cutting edges were investigated by experiments in precision hard part machining hardened GCr15 bearing steel with BZN8200 PCBN tool. With the improved chip loads, constitutive model and chip flow angle model, the predicted cutting forces show great agreement with the experimental results and verified the reliability of an improved cutting force model.

Stability Predictions for End Milling Operations With a Nonlinear Cutting Force Model

2009 ◽  
Vol 131 (6) ◽  
Author(s):  
Alex Elías-Zúñiga ◽  
Jovanny Pacheco-Bolívar ◽  
Francisco Araya ◽  
Alejandro Martínez-López ◽  
Oscar Martínez-Romero ◽  
...  
Keyword(s):  
Experimental Data ◽  
Cutting Force ◽  
End Milling ◽  
Stability Conditions ◽  
Force Model ◽  
Process Stability ◽  
Cutting Force Model ◽  
Stability Lobes ◽  
Milling Operations ◽  
The Stability

The aim of this paper is to obtain the stability lobes for milling operations with a nonlinear cutting force model. The work is focused on the generation of stability lobes based on a formulation with Chebyshev polynomials and the semidiscretization method, considering a nonlinear cutting force model. Comparisons were conducted between experimental data at 5% radial immersion with aluminum workpiece and predictions based on Chebyshev and semidiscretization. In all cases, the use of nonlinear cutting force model provides better prediction of process stability conditions.

Efficient, Accurate Geometric Modeling for Three-Axis Sculptured Surfaces Milling

2010 ◽  
Author(s):  
Qiang Fu ◽  
Zezhong C. Chen
Keyword(s):  
Cutting Force ◽  
Geometric Modeling ◽  
Geometric Approach ◽  
Milling Process ◽  
Test Surface ◽  
Force Model ◽  
Sculptured Surfaces ◽  
Computationally Efficient ◽  
Cutting Force Model ◽  
Chip Removal

Efficient, accurate geometric modeling for three-axis sculptured surfaces milling is quite challenging due to complexity of workpiece geometry change during machining. This paper presents an efficient, accurate approach to extracting the cutter/workpiece engagement (CWE) geometry and applying this geometry to an existing mechanistic force model in order to predict instantaneous cutting force, torque and power. In our research, a basic geometric modeling of chip removal in three-axis milling is investigated, and an effective model is proposed to represent the cutter swept profile. Computationally efficient, closed-form formulations are derived for general APT (Automatically Programmed Tools) cutter geometry. A Z-level B-Rep model is adopted to represent the in-process workpiece model, and an innovative geometric approach is used to extract the CWE geometry. Then, a mechanistic cutting force model is integrated to predict the cutting forces. As a result, a milling process simulation system is developed for three-axis virtual milling of sculptured surfaces. The developed system is experimentally verified by comparing the simulation results with actual forces measured from machining a test surface.

Dynamic simulation of milling operations with small diameter milling cutters: effect of material heterogeneity on the cutting force model

Meccanica ◽  
2016 ◽  
Vol 52 (1-2) ◽  
pp. 35-44 ◽  
Author(s):  
Edouard Rivière-Lorphèvre ◽  
Christophe Letot ◽  
François Ducobu ◽  
Pierre Dehombreux ◽  
Enrico Filippi
Keyword(s):  
Cutting Force ◽  
Dynamic Simulation ◽  
Small Diameter ◽  
Force Model ◽  
Cutting Force Model ◽  
Material Heterogeneity ◽  
Milling Operations

Determination of Cutting Forces for Micro Milling

2008 ◽  
Author(s):  
Shih-Ming Wang ◽  
Zou-Sung Chiang ◽  
Da-Fun Chen
Keyword(s):  
Cutting Force ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Micro Milling ◽  
Force Model ◽  
Machining Parameters ◽  
Cutting Force Model ◽  
Optimal Cutting Parameters

To enhance the implementation of micro milling, it is necessary to clearly understand the dynamic characteristics of micro milling so that proper machining parameters can be used to meet the requirements of application. By taking the effect of minimum chip thickness and rake angle into account, a new cutting force model of micro-milling which is function the instantaneous cutting area and machining coefficients was developed. According to the instantaneous rotation trajectory of cutting edge, the cutting area projected to xy-plane was determined by rectangular integral method, and used to solve the instantaneous cutting area. After the machining coefficients were solved, the cutting force of micro-milling for different radial depths of cut and different axial depths of cut can be predicted. The results of micro-milling experimental have shown that the force model can predict the cutting force accurately by which the optimal cutting parameters can be selected for micro-milling application.

A Unified Cutting Force Model for Flat End Mills Based on Cutter Geometry and Material Properties

2016 ◽  
Vol 836-837 ◽  
pp. 408-416
Author(s):  
Xiao Dong Zhang ◽  
Ce Han ◽  
Ding Hua Zhang ◽  
Ming Luo
Keyword(s):  
Cutting Force ◽  
Material Properties ◽  
Maximum Shear Stress ◽  
Cutting Parameters ◽  
Flow Rule ◽  
Force Model ◽  
Cutting Force Model ◽  
Material Parameters ◽  
Chip Flow ◽  
End Mills

A unified oblique cutting force model for flat end mills is developed. In this model, the cutting force is bridged among cutter geometry, material properties and cutting parameters. The cutter angles, material parameters and cutting parameters are the only inputs so that the model is applicable for different cutter-workpiece combinations and cutting parameters. The parameters in the model are solved by the geometric relations, applying Maximum Shear Stress Principle and Stabler’s chip flow rule. The material parameters are identified in a new method with orthogonal milling tests. The simulation results of the proposed model are in good agreement with experiments.

scholarly journals Semi-Active Magnetorheological Damper Device for Chatter Mitigation during Milling of Thin-Floor Components

2020 ◽  
Vol 10 (15) ◽  
pp. 5313 ◽  
Author(s):  
Santiago Daniel Puma-Araujo ◽  
Daniel Olvera-Trejo ◽  
Oscar Martínez-Romero ◽  
Gorka Urbikain ◽  
Alex Elías-Zúñiga ◽  
...  
Keyword(s):  
Homotopy Perturbation Method ◽  
Mr Damper ◽  
Magnetorheological Damper ◽  
Force Model ◽  
Cutting Force Model ◽  
Stability Boundaries ◽  
Milling Operations ◽  
Productivity Increase ◽  
Last Stage ◽  
The Stability

The productivity during the machining of thin-floor components is limited due to unstable vibrations, which lead to poor surface quality and part rejection at the last stage of the manufacturing process. In this article, a semi-active magnetorheological damper device is designed in order to suppress chatter conditions during the milling operations of thin-floor components. To validate the performance of the magnetorheological (MR) damper device, a 1 degree of freedom experimental setup was designed to mimic the machining of thin-floor components and then, the stability boundaries were computed using the Enhance Multistage Homotopy Perturbation Method (EMHPM) together with a novel cutting force model in which the bull-nose end mill is discretized in disks. It was found that the predicted EMHPM stability lobes of the cantilever beam closely follow experimental data. The end of the paper shows that the usage of the MR damper device modifies the stability boundaries with a productivity increase by a factor of at least 3.

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