scholarly journals Prediction and Experimental Validation of Cutting Force for Bull-Nose End Mills with Lead Angle

2014 ◽  
Vol 6 ◽  
pp. 650215 ◽  
Author(s):  
Baohai Wu ◽  
Ge Gao ◽  
Ming Luo ◽  
Gongnan Xie
Keyword(s):  
Cutting Force ◽  
Experimental Validation ◽  
Force Model ◽  
Lead Angle ◽  
Tool Axis ◽  
Dynamic Cutting Force ◽  
Cutting Force Components ◽  
End Mills ◽  
Force Components ◽  
Acquisition Method

This study focuses on cutting force predictions with the tool-workpiece inclination angle in bull-nose milling based on the semimechanistic force model. By analyzing kinematics and mechanics of the bull-nose end mills during cutting, force expressions including lead angle are stated and the model is exerted on each discrete element as oblique cutting with coordinate transformation and numerical integration to obtain the dynamic cutting force components. An improved identification method considering speed variations along the tool axis is applied to calibrate coefficients. Coefficients are regarded as the function of each elemental elevation. Then, a geometry-based method to acquire cutter workpiece engagement (CWE) is proposed. Also acquisition of accurate start and exit angles on each slice is deliberated elaborately for cutters with lead or tilt angle in milling processes. Thereby, to verify the validity of the force prediction model and start-exit angle acquisition method, experiments with variable lead angles are conducted under different axial immersions. The results reveal that the presented model and approaches can predict cutting forces with high accuracy. Finally, the cutting force components under different cutter postures and conditions are analyzed to provide instructions for parameter selections.

scholarly journals Modeling and Distribution Laws of Drilling Force for Staggered Teeth BTA Deep Hole Drill

2018 ◽  
Vol 2018 ◽  
pp. 1-13 ◽  
Author(s):  
Xubo Li ◽  
Jianming Zheng ◽  
Yan Li ◽  
Lingfei Kong ◽  
Weichao Shi ◽  
...  
Keyword(s):  
Cutting Force ◽  
Friction Angle ◽  
Hole Drilling ◽  
Force Model ◽  
Deep Hole ◽  
Drilling Force ◽  
Cutting Force Components ◽  
Distribution Laws ◽  
Force Components ◽  
Thrust And Torque

The boring and trepanning association (BTA) deep hole drilling is a typical self-guiding machining method. The drilling force and its distribution laws along the cutting radius directly affect the stability of drilling and the quality of machined hole. Based on the oblique cutting theory, a novel drilling force model is developed to predict the thrust and torque for staggered teeth BTA deep hole drill with variable geometries. Using the constraint relationships between the cutting force components and cutting angles, combined with the measured drilling force during the drill entrance, the parameters of the model including normal shear angle, normal friction angle and shear stress involved in the cutting force coefficients along the cutting radius, and the axial and circumferential friction coefficients between the guide pads and the hole wall are obtained. The model-predicted drilling force is validated by experimental results.

Surface Roughness and Cutting Force Components Evaluation in Hard Turning by Differently Shaped Cutting Tools

2016 ◽  
Vol 862 ◽  
pp. 26-32 ◽  
Author(s):  
Michaela Samardžiová
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Hard Turning ◽  
Cutting Tool ◽  
Single Point ◽  
Machining Process ◽  
Tool Geometry ◽  
Machined Surface ◽  
Cutting Force Components ◽  
Force Components

There is a difference in machining by the cutting tool with defined geometry and undefined geometry. That is one of the reasons of implementation of hard turning into the machining process. In current manufacturing processes is hard turning many times used as a fine finish operation. It has many advantages – machining by single point cutting tool, high productivity, flexibility, ability to produce parts with complex shapes at one clamping. Very important is to solve machined surface quality. There is a possibility to use wiper geometry in hard turning process to achieve 3 – 4 times lower surface roughness values. Cutting parameters influence cutting process as well as cutting tool geometry. It is necessary to take into consideration cutting force components as well. Issue of the use of wiper geometry has been still insufficiently researched.

Artificial neural networks back propagation algorithm for cutting force components predictions

2013 ◽  
Vol 14 (6) ◽  
pp. 431-439 ◽  
Author(s):  
Issam Hanafi ◽  
Francisco Mata Cabrera ◽  
Abdellatif Khamlichi ◽  
Ignacio Garrido ◽  
José Tejero Manzanares
Keyword(s):  
Neural Networks ◽  
Artificial Neural Networks ◽  
Cutting Force ◽  
Back Propagation ◽  
Back Propagation Algorithm ◽  
Propagation Algorithm ◽  
Cutting Force Components ◽  
Artificial Neural ◽  
Force Components

scholarly journals Experiments in the Machining of Ice at Negative Rake Angles

1984 ◽  
Vol 30 (104) ◽  
pp. 77-81 ◽  
Author(s):  
D.K. Lieu ◽  
C.D. Mote
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Rake Angle ◽  
Cutting Depth ◽  
Orthogonal Machining ◽  
Cutting Force Components ◽  
Force Components

AbstractThe cutting force components and the cutting moment on the cutting tool were measured during the orthogonal machining of ice with cutting tools inclined at negative rake angles. The variables included the cutting depth (< 1 mm), the cutting speed (0.01 ms−1to 1 ms−1), and the rake angles (–15° to –60°). Results of the experiments showed that the cutting force components were approximately independent of cutting speed. The resultant cutting force on the tool was in a direction approximately normal to the cutting face of the tool. The magnitude of the resultant force increased with the negative rake angle. Photographs of ice-chip formation revealed continuous and segmented chips at different cutting depths.

Improved dynamic cutting force modelling in micro milling of metal matrix composites part II: Experimental validation and prediction

2019 ◽  
Vol 234 (8) ◽  
pp. 1500-1515
Author(s):  
Zhichao Niu ◽  
Kai Cheng
Keyword(s):  
Cutting Force ◽  
Metal Matrix Composites ◽  
Cutting Forces ◽  
Metal Matrix ◽  
Micro Milling ◽  
Force Model ◽  
Matrix Composites ◽  
Cutting Force Model ◽  
Side Milling ◽  
Dynamic Cutting Force

The effects of cutting dynamics and the particles' size and density cannot be ignored in micro milling of metal matrix composites. This article presents the improved dynamic cutting force modelling for micro milling of metal matrix composites based on the previous analytical model. This comprehensive improved cutting force model, taking the influence of the tool run-out, actual chip thickness and resultant tool tip trajectory into account, is evaluated and validated through well-designed machining trials. A series of side milling experiments using straight flutes polycrystalline diamond end mills are carried out on the metal matrix composite workpiece under various cutting conditions. Subsequently, the measured cutting forces are compensated by a Kalman filter to achieve the accurate cutting forces. These are further compared with the predicted cutting forces to validate the proposed dynamic cutting force model. The experimental results indicate that the predicted and measured cutting forces in micro milling of metal matrix composites are in good agreement.

scholarly journals The mathematical models for cutting force calculation during structural and corrosion-resistant steels` parts processing

2019 ◽  
Vol 298 ◽  
pp. 00099
Author(s):  
Alexey A. Zhdanov ◽  
Oleg A. Kursin ◽  
Pham Xuan Bach
Keyword(s):  
Mathematical Models ◽  
Cutting Force ◽  
Experimental Studies ◽  
Additional Parameter ◽  
Corrosion Resistant ◽  
Cutting Force Components ◽  
Force Components ◽  
Quantitative Indicators ◽  
Force Calculation ◽  
Thermo Physical Properties

The paper shows that conventional mathematical models for calculating the cutting force components during the turning process, represented in reference guides on engineering, give drastic errors reaching 100 percent or more for various tool-workpiece couples. These errors interfere with applying reference values of the cutting force for any further calculations, equipment selection, workpiece positioning scheme, workpiece deformation value due to the elastic of the technological system elements during processing and etc., because of the insufficient reliability of the results of such calculations. The paper proposes mathematical models obtained as a result of experimental studies, which allow for increasing the accuracy of the calculation of the components of the cutting force by introducing an additional parameter – i.e., the value of thermo EMF of the test running into the calculation formulas. This approach enables to reduce the error in the calculation of the components of the cutting force up to ± 15%. In addition, the need for the development of specific mathematical models for various groups of materials machined is shown, which is due to the peculiarities of contact processes in the machining of various groups of steels, as well as to qualitative and quantitative indicators of the thermo-physical properties of the materials of tool-workpiece contact couples.

A unified instantaneous cutting force model for flat end mills with variable geometries

2014 ◽  
Vol 214 (3) ◽  
pp. 641-650 ◽  
Author(s):  
Min Wan ◽  
Wen-Jie Pan ◽  
Wei-Hong Zhang ◽  
Ying-Chao Ma ◽  
Yun Yang
Keyword(s):  
Cutting Force ◽  
Force Model ◽  
Cutting Force Model ◽  
End Mills
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