Modeling of the Thread Milling Operation in a Combined Thread/Drilling Operation: Thrilling

2010 ◽  
Vol 132 (1) ◽  
Author(s):  
Martin B. G. Jun ◽  
Anna Carla Araujo
Keyword(s):  
Cutting Force ◽  
Model Comparison ◽  
Complex Geometry ◽  
Chip Thickness ◽  
Force Model ◽  
Cutting Force Model ◽  
Tool Paths ◽  
Milling Operation ◽  
Thread Milling ◽  
Simulation Results

This paper investigates a thread making process called thrilling, which performs both drilling and thread milling with one tool. A chip thickness and mechanistic cutting force model has been developed for a thread milling operation with a thrilling tool. The model considers the complex geometry of a thrilling tool and the unique tool paths associated with the thread milling operation. Experiments have been conducted to validate the developed model. Comparison of the average torque and forces between experiment and simulation results shows that the model predicts the experimental results within 12% error.

scholarly journals Modeling and Analysis of the Thread Milling Operation in the Combined Drilling/Thread Milling Process

2008 ◽  
Author(s):  
Martin B. G. Jun ◽  
Anna Carla Araujo
Keyword(s):  
Model Comparison ◽  
Complex Geometry ◽  
Chip Thickness ◽  
Helix Angle ◽  
Milling Process ◽  
Force Model ◽  
Modeling And Analysis ◽  
Cutting Coefficients ◽  
Milling Operation ◽  
Thread Milling

This paper investigates a thread making process called thrilling, which performs both drilling and thread milling with one tool. A chip thickness and mechanistic cutting force model has been developed for a thread milling operation with a thrilling tool. The model considers the complex geometry of a thrilling tool and the unique tool paths associated with the thread milling operation. Calibration experiments have been conducted to estimate the cutting coefficients associated with specific cutting energies. Experiments have been conducted to validate the developed model. Comparison of the average torque and forces between experiment and simulation results shows that the model predicts the experimental results within 12% error. The model has also been used to analyze the effects of helix angle and number of engaged threads on the cutting forces.

Efficient Prediction of Runout Parameters in End Milling Operation

2013 ◽  
Vol 681 ◽  
pp. 186-190
Author(s):  
Jian Min Zuo ◽  
Ling Wu ◽  
Mu Lan Wang ◽  
Bao Sheng Wang ◽  
Jun Ming Hou ◽  
...  
Keyword(s):  
Data Processing ◽  
Cutting Force ◽  
End Milling ◽  
Force Model ◽  
Cutter Runout ◽  
Cutting Force Model ◽  
Adjacent Tooth ◽  
Milling Operation ◽  
Efficient Prediction ◽  
The Difference

This paper aims at studying a method to identify the cutter runout parameters for end milling. An analytical cutting force model for end milling is proposed to predict cutting force. The cutting force is separated into a nominal component independent of the cutter runout and a perturbation component induced by the cutter runout. Using the cutting force acting on the and directions to calculate the difference between the cutting radius of the adjacent tooth. Then runout parameters are obtained after a series of data processing. The simulation and the experimented results are made to validate the presented methods.

A 3-D Closed-Form Cutting Force Model for End Milling With Application to Sculptured Surface Milling

1999 ◽  
Author(s):  
T. S. Lee ◽  
R. Farahati ◽  
Y. J. Lin
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Free Form ◽  
Depth Of Cut ◽  
Force Model ◽  
Sculptured Surface ◽  
Cutting Force Model ◽  
Estimation Scheme ◽  
Simulation Results ◽  
Axial Depth

Abstract A comprehensive, 3D mathematical model of desired/optimal cutting force for end milling of free-form surfaces is proposed in this paper. The closed-form predictive model is developed based on a perceptive cutting approach resulting in a cutting force model having a comprehensive set of essential cutting parameters. In particular, the normal rake angle usually missing in most existing models of the same sort is included in the developed model. The model also enables quantitative analyses of the effect of any parameters on the cutting performance of the tool, providing a guideline to improving the tool performance. Since the axial depth of cut varies with time when milling sculptured surface parts, an innovative axial depth of cut estimation scheme is proposed for the generation of 3-D cutting forces. This estimation scheme improves the practicality of most existing predictive cutting force model for milling in which the major attention has been focused on planar milling surface generation. In addition, the proposed model takes the rake surface on the flute of mills as an osculating plane to yield 3-D cutting force expressions with only two steps. This approach greatly reduces the time-consuming mathematical work normally required for obtaining the cutting force expressions. A series of milling simulations for machining free-form parts under scenario cutting conditions have been performed to verify the effectiveness of the proposed cutting force model. The simulation results demonstrate accurate estimating capability of the proposed method for the axial depth of cut estimation. The cutting force responses from the simulation exhibit the same trends as what can be obtained using the empirical mechanic’s model referenced in the literature. Finally, through the simulation results it is also learned that designing a tool with a combination of different helix angles having cutting force signatures similar to that of the single helix angle counterparts is particularly advantageous.

A Mechanistic Cutting Force Model for 3D Ball-end Milling

2000 ◽  
Vol 123 (1) ◽  
pp. 23-29 ◽  
Author(s):  
Hsi-Yung Feng ◽  
Ning Su
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Chip Thickness ◽  
Milling Process ◽  
Force Model ◽  
Cutting Force Model ◽  
Ball End Milling ◽  
End Milling Process ◽  
Force Relationship

This paper presents an improved mechanistic cutting force model for the ball-end milling process. The objective is to accurately model the cutting forces for nonhorizontal and cross-feed cutter movements in 3D finishing ball-end milling. Main features of the model include: (1) a robust cut geometry identification method to establish the complicated engaged area on the cutter; (2) a generalized algorithm to determine the undeformed chip thickness for each engaged cutting edge element; and (3) a comprehensive empirical chip-force relationship to characterize nonhorizontal cutting mechanics. Experimental results have shown that the present model gives excellent predictions of cutting forces in 3D ball-end milling.

An Improved Tool Path Model Including Periodic Delay for Chatter Prediction in Milling

2006 ◽  
Vol 2 (2) ◽  
pp. 167-179 ◽  
Author(s):  
R. P. H. Faassen ◽  
N. van de Wouw ◽  
H. Nijmeijer ◽  
J. A. J. Oosterling
Keyword(s):  
Periodic Solution ◽  
Cutting Force ◽  
Tool Path ◽  
Chip Thickness ◽  
Milling Process ◽  
Path Model ◽  
Force Model ◽  
Cutting Force Model ◽  
Periodic Delay ◽  
The Stability

The efficiency of the high-speed milling process is often limited by the occurrence of chatter. In order to predict the occurrence of chatter, accurate models are necessary. In most models regarding milling, the cutter is assumed to follow a circular tooth path. However, the real tool path is trochoidal in the ideal case, i.e., without vibrations of the tool. Therefore, models using a circular tool path lead to errors, especially when the cutting angle is close to 0 or π radians. An updated model for the milling process is presented which features a model of the undeformed chip thickness and a time-periodic delay. In combination with this tool path model, a nonlinear cutting force model is used, to include the dependency of the chatter boundary on the feed rate. The stability of the milling system, and hence the occurrence of chatter, is investigated using both the traditional and the trochoidal model by means of the semi-discretization method. Due to the combination of this updated tool path model with a nonlinear cutting force model, the periodic solution of this system, representing a chatter-free process, needs to be computed before the stability can be investigated. This periodic solution is computed using a finite difference method for delay-differential equations. Especially for low immersion cuts, the stability lobes diagram (SLD) using the updated model shows significant differences compared to the SLD using the traditional model. Also the use of the nonlinear cutting force model results in significant differences in the SLD compared to the linear cutting force model.

Model of End Milling Force Based on Undeformed Chip Surface with NURBS in Peripheral Milling

2010 ◽  
Vol 33 ◽  
pp. 356-362 ◽  
Author(s):  
Xionig Ying Pu ◽  
Wei Jun Liu ◽  
Ji Bin Zhao
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Chip Thickness ◽  
Contact Length ◽  
Force Model ◽  
Cutting Force Model ◽  
Peripheral Milling ◽  
Chip Surface ◽  
Chip Area ◽  
Differential Element

A new cutting force model for peripheral milling is presented based-on a developed algorithm for instantaneous undeformed chip surface with NURBS. To decrease the number of the differential element, the contact cutting edges of end-milling cutter with the part and the chip thickness curve are represented by NURBS helix, and the instantaneous undeformed chip is constructed as a ruled surface with the two curves. The cutting force generated by the edge contact length and the uncut chip area. Using the cutting coefficients from Budak[1] , the cutting-force model verified by simulation. The simulation results indicate that new cutting-force model predict the cutting forces in peripheral milling accurately.

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.

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