Cutting Process Simulation in Micro Dimple Machining

2019 ◽  
Author(s):  
Takashi Matsumura ◽  
Yuji Musha
Keyword(s):  
Cutting Forces ◽  
Rotation Axis ◽  
Flow Direction ◽  
Mechanistic Model ◽  
Cutting Parameters ◽  
Process Models ◽  
Cutting Process ◽  
High Rate ◽  
Force Model ◽  
Micro Dimple

Abstract The paper discusses micro dimple millings with inclined ball end mills. Cutting process models are presented to control the dimple shapes and predict the cutting forces. In micro dimple milling, the cutter rotation axis is inclined to have the non-cutting time, during which the cutting edges don’t remove the material in a rotation of cutter. The end mill is fed at a high rate so that the machining areas removed by the cutting edges are not overlapped each other. The shapes and the alignment of the dimples are simulated for the cutting parameters in the mechanistic model. Then, the cutting forces are predicted for high machining accuracies. The cutting experiments were conducted to verify the micro dimple machining. The dimple shape model is validated in comparison between the simulated and the actual dimple shapes. The cutting forces are simulated to compare the measured ones. The force model works well to predict the cutting forces with the chip flow direction during a rotation of the cutter.

Predictive Cutting Force Model and Cutting Force Chart for Milling with Cutter Axis Inclination

2013 ◽  
Vol 7 (1) ◽  
pp. 30-38 ◽  
Author(s):  
Takashi Matsumura ◽  
◽  
Motohiro Shimada ◽  
Kazunari Teramoto ◽  
Eiji Usui ◽  
...  
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Flow Direction ◽  
Three Dimensional ◽  
Shear Plane ◽  
Cutting Parameters ◽  
Force Model ◽  
Chip Flow ◽  
Inclination Angles ◽  
Cutting Model

A force model for milling with cutter axis inclination is presented. The model predicts the cutting force and chip flow direction. Three-dimensional chip flow is interpreted as a piling up of the orthogonal cuttings in the planes containing the cutting velocities and the chip flow velocities in the inclined coordinate system with a ball end mill. The chip flow direction is determined to minimize the cutting energy consumed into the shear energy on the shear plane and the friction energy on the rake face. Then, the cutting force is predicted in the chip flow determined model. The presented cutting model is verified by comparing the predicted cutting forces to the measured forces in the actual cutting tests. As an advantage of the presented force model, the change in the chip flow direction during one rotation of the cutter is also predicted in the simulation for the cutter axis inclination and the cutting parameters. In the simulation, the effect of cutter axis inclination on the cutting process is discussed in terms of the tool wear and surface finish. The cutting force charts, in which the maximum values of the positive and the negative cutting forces are simulated for the inclination angles, are presented to review the cutter axis inclination. The applicable cutter axis inclination can be determined by taking into account the thresholds of the cutting force components.

scholarly journals Adaptive Cutting Force Prediction in Milling Processes

2010 ◽  
Vol 4 (3) ◽  
pp. 221-228 ◽  
Author(s):  
Takashi Matsumura ◽  
◽  
Takahiro Shirakashi ◽  
Eiji Usui
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Flow Model ◽  
Flow Direction ◽  
Orthogonal Cutting ◽  
Cutting Parameters ◽  
Milling Process ◽  
Force Model ◽  
Cutting Force Prediction ◽  
Chip Flow

An adaptive force model is presented to predict the cutting force and the chip flow direction in milling. The chip flow model in the milling process is made by piling up the orthogonal cuttings in the planes containing the cutting velocities and the chip flow velocities. The chip flow direction is determined to minimize the cutting energy. The cutting force is predicted using the determined chip flow model. The force model requires the orthogonal cutting data, which associate the orthogonal cutting models with the cutting parameters. Basically, the required data for simulation can be measured in the orthogonal cutting tests. However, it is difficult to perform the cutting tests with specialized setups in the machine shops. The paper presents the adaptive model to accumulate and update the orthogonal cutting data with referring the measured cutting forces in milling. The orthogonal cutting data are identified to minimize the error between the predicted and the measured cutting forces. Then, the cutting forces can be predicted well in many cutting operations using the identified orthogonal cutting data. The adaptive is effective not only in extending the database but also in improving the quality of the database for the accurate predictions.

scholarly journals A 6-Components Mechanistic Model of Cutting Actions in Milling

2021 ◽  
Author(s):  
Maël Jeulin ◽  
Olivier Cahuc ◽  
Philippe Darnis ◽  
Raynald Laheurte
Keyword(s):  
Energy Balance ◽  
Experimental Model ◽  
Cutting Forces ◽  
Mechanistic Model ◽  
Cutting Parameters ◽  
Point Of View ◽  
Stress Fields ◽  
Mechanistic Modelling ◽  
Cutting Zone ◽  
Energetic Point

Abstract Most of the cutting models developed in the literature attest only to the presence of cutting forces in the balance of mechanical actions resulting from cutting. However, several studies have highlighted the presence of cutting moments during machining, and particularly 3D cutting in milling. The objective of this paper is to characterise phenomena associated with cutting moments by performing experimental mechanistic modelling in 3D cutting. For this purpose, several modelling factors will be investigated, such as the 3D cutting reference frame, the undeformed chip section, the cutting parameters, the cutting zone, etc. The predictive model of this study proves to be relatively efficient for an experimental model and allows a global prediction of cutting moments in milling. Furthermore, beyond the aspect of stress fields in the workpiece caused by cutting moments, this paper gives perspectives from an energetic point of view for which the share of moments in the energy balance could be substantial for monobloc tools.

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.

Integration of On-Machine Measurements in the Force Modeling for Machining of Advanced Nickel-Based Superalloys

2012 ◽  
Author(s):  
Andrew Henderson ◽  
Cristina Bunget ◽  
Thomas Kurfess
Keyword(s):  
Cutting Forces ◽  
Gas Turbines ◽  
High Strength ◽  
Extreme Environment ◽  
Subsurface Damage ◽  
Process Models ◽  
Force Model ◽  
Jet Engines ◽  
Part Quality ◽  
Force Modeling

Nickel-based superalloys are specially designed for applications where high strength, creep resistance, and oxidation resistance are critical at high temperatures. Many of their applications are the hot gas sections of turbo-machinery (e.g. jet engines and gas turbines). With greater demands on the performance and efficiency of these types of machines, the firing temperatures are reaching higher levels and nickel-based superalloys are being utilized more because of their excellent mechanical qualities at extreme temperatures. However, the properties that make them attractive for these applications present difficult challenges for the manufacture, particularly machining, of the components that are made from these materials. Considering the extreme environment that these components operate in, part quality, in particular surface quality, is paramount. The damage and stresses introduced to the surfaces of these components during manufacture needs to be well understood and controlled in order to ensure that premature component and machine failures do not occur. With improved process models and on-machine measurement capabilities, the in-process cutting forces and temperatures can be better understood and therefore subsurface damage can be better controlled. Since cutting forces and temperatures are direct contributors to subsurface damage, better control of these aspects would then lead to better control of subsurface damage. This paper discusses the use of on-machine touch probes to measure wear on milling tools and using those measurements to update a mechanistic force model for more accurate prediction of the cutting forces incurred during the milling of nickel-based superalloys.

Characterization and Micromilling of Flow Induced Aligned Carbon Nanotube Nanocomposites

2013 ◽  
Vol 1 (1) ◽  
Author(s):  
Mehdi Mahmoodi ◽  
M. G. Mostofa ◽  
Martin Jun ◽  
Simon S. Park
Keyword(s):  
Thermal Conductivity ◽  
Carbon Nanotube ◽  
Cutting Forces ◽  
End Milling ◽  
Flow Direction ◽  
High Strength ◽  
Force Model ◽  
Micro End Milling ◽  
Different Characteristics ◽  
Milling Forces

Carbon nanotube (CNT) based polymeric composites exhibit high strength and thermal conductivity and can be electrically conductive at a low percolation threshold. CNT nanocomposites with polystyrene (PS) thermoplastic matrix were injection-molded and high shear stress in the flow direction enabled partial alignment of the CNTs. The samples with different CNT concentrations were prepared to study the effect of CNT concentration on the cutting behavior of the samples. Characterizations of CNT polymer composites were studied to relate different characteristics of materials such as thermal conductivity and mechanical properties to micromachining. Micro-end milling was performed to understand the material removal behavior of CNT nanocomposites. It was found that CNT alignment and concentrations influenced the cutting forces. The mechanistic micromilling force model was used to predict the cutting forces. The force model has been verified with the experimental milling forces. The machinability of the CNT nanocomposites was better than that of pure polymer due to the improved thermal conductivity and mechanical characteristics.

Uncertainty Management of Cutting Forces Parameters and its Effects on Machining Stability

2015 ◽  
Vol 651-653 ◽  
pp. 1165-1170 ◽  
Author(s):  
Edouard Rivière Lorphèvre ◽  
Christophe Letot ◽  
François Ducobu ◽  
Enrico Filippi
Keyword(s):  
Cutting Forces ◽  
Mechanistic Model ◽  
Model Identification ◽  
Cutting Parameters ◽  
Virtual Manufacturing ◽  
Production Costs ◽  
Machining Process ◽  
Macroscopic Models ◽  
Force Signal ◽  
Machining Operations

Virtual manufacturing is a field of research which numerically simulate all the manufacturing processes seen by a mechanical part during its production (for example casting, forging, machining, heat treatment,…). Its use is rising on various industries to reduce production costs and improve quality of manufactured parts. One of the most challenging component of the whole simulation chain is the simulation of machining operations due to some of its specificities (need of material law at high strain, strain rates and temperature, heterogeneities of machined material, influence of residual stresses,…).In order to circumvent these difficulties, macroscopic models of machining process have been developed in order to compute more global information (cutting forces, stability of the process, tolerance or roughness for example). For this approach, the cutting forces computation is done by using simple analytical law based on mechanistic approach. The parameters of the models have no clear physical meaning (or at least cannot be linked to intrinsic properties of the material to be machined) and are therefore considered constants for a given set of simulations.The aim of this paper is to take into account the uncertainty on the variability of the cutting force signal during machining operation used as input for mechanistic model identification. The variability of the response during a test on fixed conditions (cutting tool, machined material and cutting parameters) is taken into account to develop a model where parameters of the model can evolve during a given operation.The proposed model is then used as an input of a milling operation simulation in order to study its influence on machining stability as compared to a classical approach.

Cutting Force Model of Aluminum Alloy 2014 in Turning with ANOVA Analysis

2010 ◽  
Vol 42 ◽  
pp. 242-245
Author(s):  
Yong Jie Ma ◽  
Yi Du Zhang ◽  
Xiao Ci Zhao
Keyword(s):  
Aluminum Alloy ◽  
Cutting Force ◽  
Response Surface ◽  
Cutting Forces ◽  
Cutting Parameters ◽  
Quadratic Model ◽  
Surface Model ◽  
Force Model ◽  
Machining Parameters ◽  
Cutting Force Model

In the present study, aluminum alloy 2014 was selected as workpiece material, cutting forces were measured under turning conditions. Cutting parameters, the depth of cut, feed rate, the cutting speed, were considered to arrange the test research. Mathematical model of turning force was solved through response surface methodology (RSM). The fitting of response surface model for the data was studied by analysis of variance (ANOVA). The quadratic model of RSM associated with response optimization technique and composite desirability was used to find optimum values of machining parameters with respect to cutting force values. The turning force coefficients in the model were calibrated with the test results, and the suggested models of cutting forces adequately map within the limits of the cutting parameters considered. Experimental results suggested that the most cutting force among three cutting forces was main cutting force. Main influencing factor on cutting forces was obtained through cutting force models and correlation analysis. Cutting force has a significant influence on the part quality. Based on the cutting force model, a few case studies could be presented to investigate the precision machining of aluminum alloy 2014 thin walled parts.

scholarly journals Influence of stiffness of the mechanical part of the drive and cutting parameters on the shaping elastic deformation control

2021 ◽  
Vol 21 (2) ◽  
pp. 154-162
Author(s):  
V. L. Zakovorotny ◽  
V. Е. Gvindjiliya ◽  
А. А. Zakalyuzhny
Keyword(s):  
Feed Rate ◽  
Cutting Forces ◽  
Tool Path ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Return Flow ◽  
Elastic Deformations ◽  
Mechanical Part ◽  
Feed Drive ◽  
The Law

Introduction. One of the ways to improve the accuracy of manufacturing parts by cutting is related to the control of elastic deformations of the tool and the workpiece. This is particularly true for slender parts, whose stiffness law along the tool path is given. In this case, the control parameter, as a rule, is the return flow rate, which affects the cutting forces, whose change causes variations in elastic deformations. To provide the specified accuracy of the diameter, it is required to coordinate the controlled trajectory of the feed drive speed with the feed rate and a priori given law of change in the stiffness of the workpiece or the law of variation of the cutting process parameters. To do this, it is required to determine the law of converting the engine speed into the feed rate, and, ultimately, into elastic deformations. This law depends on the stiffness of the mechanical part of the feed drive and the changing parameters of the cutting process.Materials and Methods. The paper presents mathematical modeling and, on its basis, analysis of the conversion of the feed rate into cutting forces, taking into account the final stiffness value of the mechanical part of the drive and the evolutionary parameters of the cutting process.  Results. It is shown that, starting from a certain critical value, the law of converting the feed rate into cutting forces becomes fundamentally dependent on the stiffness of the mechanical part of the drive. At the same time, there is an increase in time for setting a new force value when the feed rate varies, which affects the accuracy of providing forces that are consistent with the stiffness law of the part. The paper presents algorithms for calculating elastic deformations for a given stiffness law, as well as algorithms for calculating the trajectory of the feed rate at which the deformations remain constant. It is shown that the law of conversion is also affected by variations in the cutting parameters. Discussion and Conclusion. The frequency and time characteristics of the conversion are discussed. A conclusion is made about the accuracy of the diameter formed through cutting, depending on the stiffness of the mechanical part of the feed drive and on some parameters of the cutting process. 

The Friction Coefficient and Self-Organization Feature on Rake Face when Turning Hardened Steel with Coating Tools

2010 ◽  
Vol 97-101 ◽  
pp. 1871-1874 ◽  
Author(s):  
Zhi Gang Hou ◽  
Jun Zhao ◽  
Li Qiang Xu ◽  
Zhong Guo
Keyword(s):  
Friction Coefficient ◽  
Experimental Method ◽  
Cutting Forces ◽  
Cutting Parameters ◽  
Hardened Steel ◽  
The Self ◽  
Cutting Process ◽  
Self Organization ◽  
Rake Face ◽  
Cutting Experiments

The friction coefficient on rake face was calculated through the cutting forces tested in a series of cutting experiments. These experiments were performed for turning two kinds of hardened steel with four types of coating tool by orthogonal experimental method. The curves of the friction coefficient changing with the cutting process and its dependence on the cutting parameters were analyzed in detail. The results show that the friction coefficient on rake face decreases rapidly during the cutting progress and comes to a steady value, which could be an indication of the self-organization when turning hardened steel with coating tool.

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