scholarly journals Uniformity, Periodicity and Symmetry Characteristics of Forces Fluctuation in Helical-Edge Milling Cutter

2021 ◽  
Vol 11 (6) ◽  
pp. 2693
Author(s):  
Boyang Meng ◽  
Xianli Liu ◽  
Maoyue Li ◽  
Steven Y. Liang ◽  
Lihui Wang ◽  
...  
Keyword(s):  
Estimation Method ◽  
Chip Thickness ◽  
Simulation Method ◽  
Milling Process ◽  
Milling Force ◽  
Force Fluctuation ◽  
Force Transformation ◽  
Experimental Cutting ◽  
First Time ◽  
Mathematical Derivation

Under most processing conditions, the milling force is expected to be stable and not to fluctuate, in order to improve the processing quality. This study focuses on analyzing the force fluctuation characteristics under conditions of different processing and cutter parameters. An original model is proposed to predict the force fluctuation during the milling process of a helical-edge cutter. At the same time, three force fluctuation characteristics related to the axial cutting depth and cutter parameters are determined: uniformity, periodicity and symmetry. The corresponding mathematical derivation and proof method are given for the first time through a force transformation of projecting the superposition chip thickness on a virtual cutting edge. On this basis, a fast estimation method and an accurate simulation method for force fluctuation prediction are established to quantify the intensity of force fluctuations under different parameters. Both two prediction methods and the experimental cutting tests validate the proposed theory effectively. The result shows a high potential of the proposed theory for studying the force behavior under different milling parameters or cutter parameters and at least 75% of the test workload can be reduced.

scholarly journals VALIDATION OF CUTTING FORCE CHARACTERISTIC FOR COMPLEX TOOLPATH

2016 ◽  
Vol 3 ◽  
pp. 78-81
Author(s):  
Henrik Tamás Sykora ◽  
Attila Kovács ◽  
Dániel Bachrathy
Keyword(s):  
Cutting Force ◽  
Tool Path ◽  
Removal Rate ◽  
Chip Thickness ◽  
Simulation Method ◽  
Milling Process ◽  
Simulation Software ◽  
Force Characteristic ◽  
Force Model ◽  
Force Data

In the design phase of the milling process, there is a great need for the prediction of the cutting force, the required torque and power of the spindle. These informations could be used to optimize the tool path and improve the material removal rate. In this work, we present our dexel based simulation software, its modules, calculations steps and the simulation method. Different force models were analysed to describe the specific force as a function of the local chip thickness. The models were fitted to the measured force data. Then the selected force model was validated in case of a complex tool path.

Research on Error Compensation of Corner Milling Process Based on Milling Force Prediction

2014 ◽  
Vol 800-801 ◽  
pp. 761-765
Author(s):  
Hui Nan Shi ◽  
Fu Gang Yan ◽  
Yun Peng Ding ◽  
Xian Li Liu ◽  
Rui Zhang
Keyword(s):  
Error Compensation ◽  
Chip Thickness ◽  
Milling Process ◽  
Force Model ◽  
Deformation Model ◽  
Milling Force ◽  
Element Analysis ◽  
The Finite Element Analysis ◽  
Flexible Deformation ◽  
Milling Force Model

In cavity die corner-machining, tool flexible deformation caused by the milling force resulting in the surface error, a method of off-line error compensation is put forward. Instantaneous chip thickness model and the corner milling force model is established based on differential and the characteristics of the corner. Combining the theory of cantilever beam and the finite element analysis, cutting tool elastic deformation model is established.

Modeling of dynamic milling forces considering the interlaminar effect during milling multidirectional CFRP laminate

2020 ◽  
pp. 073168442097176
Author(s):  
Fuji Wang ◽  
Guangjian Bi ◽  
Fuda Ning
Keyword(s):  
Superposition Principle ◽  
Milling Process ◽  
Force Model ◽  
Milling Force ◽  
Cfrp Laminate ◽  
Near Net Shape ◽  
Milling Forces ◽  
Milling Force Model ◽  
First Time

The milling process is always required to achieve dimensional tolerance for the near-net-shape carbon fiber reinforced polymer (CFRP) parts. However, delamination and cracking are inevitably induced in milling CFRP due to the excessive milling forces. The milling forces should be thereby well controlled to reduce damages of CFRP parts. Developing a theoretical milling force model is an effective approach to understand the mechanism of milling force generation. Recent studies have established the predictive models; however, the interlaminar effect impacting the material removal process is not considered during milling multidirectional CFRP laminate, limiting the predictive model accuracy. In this work, a model of dynamic milling force for multidirectional CFRP laminate was developed by considering the interlaminar effect for the first time. The specific cutting energy predicted by the artificial neural network methodology was employed to calculate the milling forces during milling a single CFRP layer. Meantime, the support of the layer was enhanced due to the interlaminar effect, and the correction coefficients for each type of support were proposed to reflect the role of this effect. Then, the overall milling forces for multidirectional CFRP laminate can be obtained via the superposition principle, which agreed well with the experimentally measured results.

Study on Effects of Cutter Radial Runout and Deformation on Cutting Force in Ball-End Hard Milling

2011 ◽  
Vol 175 ◽  
pp. 284-288
Author(s):  
Xing Fa Zhao ◽  
Xian Li Liu ◽  
Fei Xiao ◽  
Yan Xin Wang ◽  
Yan Cui Jiang
Keyword(s):  
Three Dimensional ◽  
Chip Thickness ◽  
Milling Process ◽  
Experimental Result ◽  
Main Role ◽  
Hard Milling ◽  
Milling Force ◽  
Cutter Wear ◽  
Two Factors ◽  
Vector Direction

As cutter radial runout and deformation play a main role in processing precision, surface roughness and cutter wear during hard milling, the effects of the former two factors on actual cutting radius and cutting chip thickness are analyzed during milling process briefly in this paper. The vector direction of radius runout and deformation are assumed to be the same. Then, the milling force of cutting cutter whirling a circle is simulated under the three-dimensional feed motion, and the simulation result agrees well with the experimental result.

Modeling and Simulation of Milling Forces for Ball-End Cutter with Considering Comprehensive Factors

2011 ◽  
Vol 121-126 ◽  
pp. 2098-2104
Author(s):  
Xiu Lin Sui ◽  
Ping Zhang
Keyword(s):  
Chip Thickness ◽  
Milling Process ◽  
Differential Method ◽  
Physical Factors ◽  
Force Model ◽  
Milling Force ◽  
Cutter Deflection ◽  
Set Up ◽  
Milling Forces ◽  
Milling Force Model

In this paper, influence mechanism of variously physical factors for milling force in any feed direction is studied during the milling process. Firstly, the effects of spindle eccentricity, cutter deflection and cutter vibration for the instantaneously undeformed cutting thickness are analyzed, and the mathematical expressions of chip thickness is set up. Then,on this basis of cutting force and chip load, the milling force model of ball-end mill with considering integrated physical factors is established though the differential method, and a simulation system for prediction of milling forces during the milling process is developed. This milling force model is verified through simulation and analysis of milling forces.

Instantaneous Uncut Chip Thickness Model in End Milling Based on an Improved Method

2018 ◽  
Vol 764 ◽  
pp. 399-407
Author(s):  
Yue Zhang ◽  
Zhi Qiang Yu ◽  
Tai Yong Wang
Keyword(s):  
End Milling ◽  
Chip Thickness ◽  
Transcendental Equation ◽  
Milling Process ◽  
Force Model ◽  
Uncut Chip Thickness ◽  
Milling Force ◽  
Milling Force Model ◽  
Instantaneous Uncut Chip Thickness ◽  
Taylor’S Series

The instantaneous uncut chip thickness is an important parameter in the study of milling force model. By analyzing the real tooth trajectory in milling process, accurate instantaneous uncut chip thickness can be obtained to solve the complex transcendental equation. Traditional chip thickness models always simplify the tooth trajectory to get approximate solution. A new instantaneous uncut chip thickness model is proposed in this paper. Based on real tooth trajectory of general end milling cutter, a Taylor's series is used to approximate the involved infinitesimal variable in the transcendental equation, which results in an explicit expression for practical application of the uncut chip thickness with higher accuracy compared to the traditional model.

scholarly journals Effect of Milling Vibration on The Machining Performance of 7075-T651 Aluminum Alloys

2021 ◽  
Author(s):  
Miaoxian Guo ◽  
Jianming Wang ◽  
Jin Liu ◽  
Chao Huang ◽  
Xiaohui Jiang
Keyword(s):  
Simulation Model ◽  
End Milling ◽  
Chip Thickness ◽  
Element Model ◽  
Milling Process ◽  
Machining Performance ◽  
Milling Force ◽  
Milling Temperature ◽  
The Relationship ◽  
Milling Vibration

Abstract Milling of 7075-T651 is widely used in aerospace industry, however the process vibration restricts the machining performance in milling process. This paper puts forward a study on the effect of vibration on machining performance in milling to improve the machining quality. According to the characteristics of end milling, the process vibration is calculated and added based on the unformed chip thickness model of milling, and a milling simulation model considering vibration is established. Applying the finite element model and milling experiments, the simulation model is verified, the results proves the accuracy of the FEM models in predicting the milling force and milling temperature. Furthermore, the effect of milling vibration on machining performance is studied by numerical simulation, in which the relationship between amplitude-frequency characteristics and milling force-temperature fluctuation.

Modeling and Simulation of Milling Force in Virtual Numerical Control Milling Process

2008 ◽  
Vol 392-394 ◽  
pp. 697-702
Author(s):  
Xiu Lin Sui ◽  
Jia Tai Zhang ◽  
Jiang Hua Ge ◽  
Ya Ping Wang ◽  
H. Yuan
Keyword(s):  
Modeling And Simulation ◽  
Chip Thickness ◽  
Milling Process ◽  
Cutting Edge ◽  
Numerical Control ◽  
Force Model ◽  
End Mill ◽  
Ball End Mill ◽  
Milling Force ◽  
Milling Force Model

A parameter equation based on cutting edge of ball-end mill is set up by analyzing the parameters of ball-end mill influence the milling force in virtual NC milling process. The relationship among elemental cutting force, instantaneous radial chip thickness and cutting edge length is analyzed, and the dynamic milling force of ball-end mill at arbitrary feed direction is established. The milling force parameter model by quadratic regression equation in different cutting conditions is built. Through experiments in NC machining center and using orthogonal combination and principal components analysis, the regression coefficients are calculated. The correctness of milling force model is testified by experiments. All these can provide theoretical basis for physics modeling and simulation of virtual numerical control milling.

scholarly journals Comparative investigation of lasing and amplification performance in cryogenic Yb:YLF systems

2021 ◽  
Vol 127 (3) ◽  
Author(s):  
Umit Demirbas ◽  
Martin Kellert ◽  
Jelto Thesinga ◽  
Yi Hua ◽  
Simon Reuter ◽  
...  
Keyword(s):  
Continuous Wave ◽  
Estimation Method ◽  
Laser Cavity ◽  
Comparative Investigation ◽  
Limiting Factor ◽  
Experimental Conditions ◽  
Temperature Estimation ◽  
Transverse Temperature ◽  
First Time

AbstractWe present detailed experimental results with cryogenic Yb:YLF gain media in rod-geometry. We have comparatively investigated continuous-wave (cw) lasing and regenerative amplification performance under different experimental conditions. In the cw lasing experiments effect of crystal doping, cw laser cavity geometry and pump wavelength on lasing performance were explored. Regenerative amplification behavior was analyzed and the role of depolarization losses on performance was investigated. A recently developed temperature estimation method was also employed for the first time in estimating average crystal temperature under lasing conditions. It is shown that the thermal lens induced by transverse temperature gradients is the main limiting factor and strategies for future improvements are discussed. To the best of our knowledge, the achieved results in this study (375 W in cw, and 90 W in regenerative amplification) are the highest average powers ever obtained from this system via employing the broadband E//a axis.

scholarly journals Nickel-Based Alloy Dry Milling Process Induced Material Softening Effect

Materials ◽  
2020 ◽  
Vol 13 (17) ◽  
pp. 3758 ◽  
Author(s):  
Jun Zha ◽  
Zelong Yuan ◽  
Hangcheng Zhang ◽  
Yipeng Li ◽  
Yaolong Chen
Keyword(s):  
High Speed ◽  
Softening Temperature ◽  
Milling Process ◽  
Dry Milling ◽  
Milling Force ◽  
Softening Effect ◽  
Milling Temperature ◽  
Nickel Based Alloy ◽  
Alloy Softening ◽  
Milling Forces

Improving the cutting efficiency is the major factor for improving the processing of nickel-based alloys. The novelty of this research is the calibrated SiAlON ceramic tool dry milling nickel-based alloy process. Firstly, the nickel-based alloy dry milling process was analyzed through the finite element method, and the required milling force and temperature were deduced. Then, several dry milling experiments were conducted with the milling temperature, and the milling force was monitored. The change in cutting speeds was from 400 m/min to 700 m/min. Experimental results verified the reduction of the dry milling force hypothesized by the simulation. The experiment also indicated that with a cut depth of 0.3 mm, cut width of 6 mm, and feed per tooth of 0.03 mm/z, when milling speed exceeded 527.52 m/min, the milling force began to decrease, and the milling temperature exceeded the nickel-based alloy softening temperature. This indicated that easy cutting could be realized under high-speed dry milling conditions. The interpolation curve about average temperature and average milling forces showed similarity to the tensile strength reduction with the rise of temperature.

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