An Improved Cutting Force Model Considering the Size Effect in End Milling

2000 ◽  
Author(s):  
Won-Soo Yun ◽  
Dong-Woo Cho
Keyword(s):  
Size Effect ◽  
Cutting Force ◽  
Cutting Forces ◽  
Measurement Problem ◽  
End Milling ◽  
Mechanistic Model ◽  
Chip Thickness ◽  
Force Model ◽  
Cutting Force Model ◽  
Approximate Methods

Abstract In this paper, a mechanistic model is first constructed to predict three-dimensional cutting forces, and the uncut chip thickness is calculated by following the movements of the position of the center of a cutter, which varies with the nominal feed, cutter deflection and runout. For general implementation to a real machining, this paper presents the method that determines constant cutting force coefficients, irrespective of the cutting conditions or cutter rotation angles. In addition, this study presents the approach which estimates runout-related parameters, the runout offset and its location angle, using only one measurement of cutting forces. For more accurate cutting force predictions, the size effect has to be considered in the cutting force model. In this paper, two approximate methods are suggested since the strict approach is practically impossible due to a measurement problem. The size effect is individually considered for narrow and wide cuts.

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.

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.

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.

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.

Convolution Analysis of Milling Force Pulsation

1994 ◽  
Vol 116 (1) ◽  
pp. 17-25 ◽  
Author(s):  
J.-J. Junz Wang ◽  
S. Y. Liang ◽  
W. J. Book
Keyword(s):  
Cutting Force ◽  
Density Function ◽  
Cutting Forces ◽  
End Milling ◽  
Chip Thickness ◽  
Closed Form Expression ◽  
Thickness Variation ◽  
Depth Of Cut ◽  
Force Model ◽  
Frequency Multiplication

This paper presents the establishment of a closed form expression for the dynamic forces as explicit functions of cutting parameters and tool/workpiece geometry in milling processes. Based on the existing local cutting force model, the generation of total cutting forces is formulated as the angular domain convolution of three cutting process component functions, namely the elementary cutting function, the chip width density function, and the tooth sequence function. The elemental cutting force function is related to the chip formation process in an elemental cutting area and it is characterized by the chip thickness variation, and radial cutting configuration. The chip width density function defines the chip width per unit cutter rotation along a cutter flute within the range of axial depth of cut. The tooth sequence function represents the spacing between flutes as well as their cutting sequence as the cutter rotates. The analysis of cutting forces is extended into the Fourier domain by taking the frequency multiplication of the transforms of the three component functions. Fourier series coefficients of the cutting forces are shown to be explicit algebraic functions of various tool parameters and cutting conditions. Numerical simulation results are presented in the frequency domain to illustrate the effects of various process parameters. A series of end milling experiments are performed and their results discussed to validate the analytical model.

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.

Calibration of a Milling Force Model Using Feed and Spindle Power Sensors

2008 ◽  
Author(s):  
Bryan Javorek ◽  
Barry K. Fussell ◽  
Robert B. Jerard
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Machining Process ◽  
Force Model ◽  
Cutting Force Model ◽  
Drive Power ◽  
Average Force ◽  
Force Monitoring ◽  
Milling Force Model

Changes in cutting forces during a milling operation can be associated with tool wear and breakage. Accurate monitoring of these cutting forces is an important step towards the automation of the machining process. However, direct force sensors, such as dynamometers, are not practical for industry application due to high costs, unwanted compliance, and workspace limitations. This paper describes a method in which power sensors on the feed and spindle motors are used to generate coefficients for a cutting force model. The resulting model accurately predicts the X and Y cutting forces observed in several simple end-milling tests, and should be capable of estimating both the peak and average force for a given cut geometry. In this work, a dynamometer is used to calibrate the feed drive power sensor and to measure experimental cutting forces for verification of the cutting force model. Measurement of the average x-axis cutting forces is currently presented as an off-line procedure performed on a sacrificial block of material. The potential development of a continuous, real-time force monitoring system is discussed.

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.

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.

Sign in / Sign up

Export Citation Format

Share Document