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.

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.

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 Gyroscopic Effect for Instantaneous Cutting Force Prediction in High-Speed Milling

2011 ◽  
Vol 418-420 ◽  
pp. 840-843
Author(s):  
Qing Hua Song ◽  
Xing Ai
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Tool Path ◽  
Milling Process ◽  
Path Model ◽  
Force Model ◽  
Cutting Force Model ◽  
Gyroscopic Effect ◽  
Cutting Force Prediction ◽  
High Speed Milling

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. With the speed increasing, gyroscopic effect plays an important pole on the system behavior, including dynamic characteristic and rotating behavior. Considering the influence of gyroscopic effect on rotating behavior, an updated model for the milling process is presented which features as model of the equivalent profile of tool. In combination with this model, a nonlinear instantaneous cutting force model is proposed. The use of this updated equivalent profile of tool results in significant differences in the static uncut thickness compared to the traditional model.

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.

scholarly journals Modeling and Estimation of Cutting Forces in Ball Helical Milling Process

2021 ◽  
Author(s):  
Haiyan Wang ◽  
Kexin Tao ◽  
Tian Jin
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Spherical Surface ◽  
Research Result ◽  
Chip Thickness ◽  
Milling Process ◽  
Helical Milling ◽  
Force Model ◽  
Cutting Force Model ◽  
Milling Forces

Abstract Milling forces play an important role in the milling process and are generally calculated by the mechanistic or numerical methods, reliable model of cutting force is very important for the simulation of milling process, which has big scientific significance to further improve machining quality. Ball helical milling technology is used to make holes based on the cutting principle of helical milling using ball end cutter, due to the influence of spherical surface machining characteristic, the modeling of cutting force in ball helical milling is difficult. Therefore, the main purpose of this paper is to first establish an analytical cutting force model in the ball helical milling process. Considering cutting characteristics in the axial feed, the kinematics of ball helical milling is first presented, then the chip thickness distribution in different directions along the cutting edges are predicted. Furthermore, based on the characteristics of helical milling technology and geometry shape of ball end mill and the classical mechanical cutting force model, through the study on the ball-end milling mechanics, a new relatively accurate theoretical cutting force model is established. At the same time, cutting force coefficients are identified through instantaneous force method according to the Ti-alloy experimental research result. Finally, higher simulation precision of cutting force model in ball helical milling process is received.

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