A Mechanistic Force Model of the 5-Axis Milling Process

2000 ◽  
Author(s):  
Paul A. Clayton ◽  
Mohamed A. Elbestawi ◽  
Tahany El-Wardany ◽  
Dan Viens
Keyword(s):  
High Speed ◽  
Mechanistic Model ◽  
Back Propagation ◽  
High Speed Steel ◽  
Cutting Edge ◽  
Analytic Description ◽  
Force Model ◽  
Force Output ◽  
Five Axis ◽  
Milling Force Model

Abstract This paper presents a five-axis milling force model that can incorporate a variety of cutters and workpiece materials. The mechanistic model uses a discretized cutting edge to calculate an area of intersection which is multiplied by the specific cutting pressure to produce a force output along the primary cartesian coordinate system. By using an analytic description of the cutting edge with a non-specific cutter and workpiece intersection routine, a model was created that can describe a variety of cutting situations. Furthermore, a back propagation neural network is used to calibrate the model, providing robustness and scalability to the calibration process. Testing was performed on 1020 steel using various cutting parameters with a high speed steel two flute cutter and a tungsten carbide insert cutter. Furthermore, both linear cuts and a test die surface yielded good agreement between predicted and measured results.

Transient Dynamic Analysis of the Matching of Lengthened Shrink-Fit Holder and Cutter in High-Speed Milling

2010 ◽  
Vol 97-101 ◽  
pp. 1819-1822 ◽  
Author(s):  
Hou Ming Zhou ◽  
Jian Xin Deng ◽  
Zhen Yu Zhao ◽  
Shi Ping Yang
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
Back Propagation ◽  
Force Model ◽  
Milling Force ◽  
Transient Dynamic Analysis ◽  
High Speed Milling ◽  
Transient Dynamic ◽  
Shrink Fit ◽  
Milling Force Model

Finite element model of the matching of lengthened shrink-fit holder (LSFH) and cutting tool is established and a milling force model is developed to predict the transient milling force exactly using back propagation neural network (BPNN). Subsequently, the transient dynamic characteristic of matching of LSFH and cutting tool is analyzed and the simulation result is obtained. Finally, the simulation result is verified with practical measurement and the results fit very well. The studies are important to optimum design and select the lengthened shrink-fit holder in high speed milling.

Milling Force Forecast of the Matching of Lengthened Shrink-Fit Holder and Cutter in High Speed Machining

2010 ◽  
Vol 139-141 ◽  
pp. 827-830
Author(s):  
Hou Ming Zhou ◽  
Jian Xin Deng ◽  
Wen Wei Xie
Keyword(s):  
High Speed ◽  
Back Propagation ◽  
Back Propagation Neural Network ◽  
Force Model ◽  
Milling Force ◽  
Matlab Program ◽  
Force Components ◽  
Shrink Fit ◽  
Milling Forces ◽  
Milling Force Model

Present work of this paper focus on developing a milling force model according to the characteristic of the matching of lengthened shrink-fit holder (LSFH) and cutter using back propagation neural network (BPNN). Time parameter is taken as a factor of the input vector besides 6 processing conditions which mainly affect the milling force, and then the forecasting of 3D transient milling forces are achieved. A lot of milling experiments were performed to get training and testing samples and a Matlab program was designed to evaluate and optimize the network. The test experiments show that the forecasting results are well agreed with the experimental results and the errors of 3D force components are less than 0.18. Besides an extended performance, the BPNN model has higher efficiency and higher accuracy than the customary analytical model.

Design of Electrolytic Strengthening Machine for Cutting Edge of Cutter

2016 ◽  
Vol 693 ◽  
pp. 1585-1590
Author(s):  
Yi Zhuo Guo ◽  
Xian Guo Yan ◽  
Shu Juan Li ◽  
Hong Guo
Keyword(s):  
Service Life ◽  
Calculation Method ◽  
High Speed ◽  
High Speed Steel ◽  
Cutting Edge ◽  
The Cost ◽  
Electric Quantity

Many studies have proved the service life of cutter can be prolonged by electrolytic strengthening. Based on the theory of electrolytic strengthening technology, this paper introduced and developed prototype equipment for strengthening cutting edge of rotary cutter and put forward a calculation method of total electric quantity consumption during the electrolysis suitable for microcontroller. The M8 high-speed steel tap is taken as a strengthening example. After finished the strengthening process that it clearly see the results of the surface of tap was obviously polished by observing the micrograph. This equipment improves the reliability of electrolytic strengthening and the cost is relatively cheap.

scholarly journals Optimization of Boring Process Parameters in Manufacturing of Polyacetal Bushing using High Speed Steel

2019 ◽  
Vol 130 ◽  
pp. 01031 ◽  
Author(s):  
The Jaya Suteja ◽  
Yon Haryono ◽  
Andri Harianto ◽  
Esti Rinawiyanti
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Feed Rate ◽  
High Speed ◽  
Removal Rate ◽  
High Speed Steel ◽  
Cutting Edge ◽  
Depth Of Cut ◽  
Optimum Result ◽  
Edge Angle

Polyacetal is commonly used as bushing material because of its low coefficient of friction and self lubricant characteristics. The polyacetal is machined by using boring process to produce bushing in certain surface roughness. The objectives of this research are to optimize three independent parameters (depth of cut, feed rate and principal cutting edge angle) of boring process of polyacetal using high speed steel tool to achieve the highest material removal rate and the required surface roughness. Response Surface Methodology is used to investigate the influence of the parameters and optimize the boring process. The research shows that the influence of the boring process parameters on polyacetal is similar compared to on metal. The result reveals that the optimum result is achieved by applying the value of depth of cut, feed rate, and principal cutting edge angle is 2.9 × 10–3 m, 0.229 mm rev–1, and 99.1° respectively. By applying these values, the maximum material rate removal achieved in this research is 1263.4 mm3 s–1 and the surface roughness achieved is 1.57 × 10–6 m.

Force Modeling of Five-Axis Microball-End Milling

2015 ◽  
Vol 3 (3) ◽  
Author(s):  
Chi Xu ◽  
James Zhu ◽  
Shiv G. Kapoor
Keyword(s):  
End Milling ◽  
Elastic Recovery ◽  
Chip Thickness ◽  
Force Model ◽  
End Mill ◽  
Data Simulation ◽  
Force Modeling ◽  
Static Indentation ◽  
Five Axis ◽  
Milling Force Model

This paper presents a five-axis ball-end milling force model that is specifically tailored to microscale machining. A composite cutting force is generated by combining two force contributions from a shearing/ploughing slip-line (SL) field model and a quasi-static indentation (ID) model. To fully capture the features of microscale five-axis machining, a unique chip thickness algorithm based on the velocity kinematics of a ball-end mill is proposed. This formulation captures intricate tool trajectories as well as readily allows the integration of runout and elastic recovery effects. A workpiece updating algorithm has also been developed to identify tool–workpiece engagement. As a dual purpose, historical elastic recovery is stored locally on the meshed workpiece surface in vector form so that the directionality of elastic recovery is preserved for future time increments. The model has been validated through a comparison with five-axis end mill force data. Simulation results show reasonably accurate replication of end milling cutting forces with minimal experimental data fitting.

Development of Multilayer Composition Thin Film Thermocouple Cutting Temperature Sensor Based on Magnetron Sputtering

2009 ◽  
Vol 69-70 ◽  
pp. 515-519 ◽  
Author(s):  
Yun Xian Cui ◽  
Bao Yuan Sun ◽  
W.Y. Ding ◽  
F.D. Sun
Keyword(s):  
Thin Film ◽  
Magnetron Sputtering ◽  
High Speed ◽  
Cutting Temperature ◽  
High Speed Steel ◽  
Plasma Source ◽  
Cutting Edge ◽  
Static Calibration ◽  
Ecr Plasma ◽  
Thin Film Thermocouple

In the paper, a new multilayer composition thin film thermocouple was developed, which can accurately measure the temperature nearby cutting edge in convenient and fast ways. By means of advanced Twinned microwave ECR plasma source enhanced Radio Frequency (RF) reaction non-balance magnetron sputtering technique, SiO2 insulating film, NiCr/NiSi sensor film and SiO2 protecting film were deposited on the surface HSS substrate. Both static calibration and dynamic calibration were completed. The results showed that the sensor had good performance, good linearity, quick dynamic response, response time constant was 12.7ms. The temperature near the cutting edge in cutting process of aluminum alloy was measured by the developed sensor. The bonding strength between multiple layer film and substrate of high-speed-steel met the presupposed demands.

COMOKUT

Alloy Digest ◽  
1953 ◽  
Vol 2 (7) ◽  
Keyword(s):  
Fracture Toughness ◽  
High Speed ◽  
High Speed Steel ◽  
Heat Treating ◽  
Cutting Edge ◽  
Bethlehem Steel Corporation ◽  
Steel Corporation

Abstract COMOKUT is a tungsten-molybdenum-chromium-vanadium-cobalt type of high-speed steel. It is particularly suitable for continuous heavy hogging cuts where high cutting-edge temperatures and pressures are developed. This datasheet provides information on composition and hardness as well as fracture toughness. It also includes information on forming, heat treating, and machining. Filing Code: TS-8. Producer or source: Bethlehem Steel Corporation.

An Investigation into the Dependency of Cutting Forces on the Volume Fraction and Fibre Orientation during Machining Composite Materials

2017 ◽  
Vol 882 ◽  
pp. 61-65
Author(s):  
Fadi Kahwash ◽  
Islam Shyha ◽  
Alireza Maheri
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Fibre Orientation ◽  
Orthogonal Cutting ◽  
Fibre Volume Fraction ◽  
High Speed Steel ◽  
Fibre Volume ◽  
Force Model ◽  
High Dependency

This paper presents an empirical force model quantifying the effect of fibre volume fraction and fibre orientation on the cutting forces during orthogonal cutting of unidirectional composites. Glass fibre plates and high speed steel cutting tools are used to perform orthogonal cutting on shaping machine whereas cutting forces are measured using platform force dynamometer. The analysis of forces shows almost linear dependency of cutting forces on the fibre content for both cutting and thrust forces. High dependency of cutting forces is also observed on fibre orientation with high percentage contribution ratio (up to 95.31%). Lowest forces corresponded to 30o and highest to 90o fibre orientation. Multivariate regression technique is used to construct the empirical model.

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