scholarly journals Cutting Forces Measurement for Milling Process by Using Working Tables with Integrated PVDF Thin-Film Sensors

Sensors ◽  
2018 ◽  
Vol 18 (11) ◽  
pp. 4031 ◽  
Author(s):  
Ming Luo ◽  
Zenghui Chong ◽  
Dongsheng Liu
Keyword(s):  
Thin Film ◽  
Cutting Force ◽  
Cutting Forces ◽  
Polyvinylidene Fluoride ◽  
Force Measurement ◽  
Milling Process ◽  
Machining Process ◽  
Signal Spectrum ◽  
Milling Force ◽  
Thin Film Sensors

In the milling process, cutting forces contain key information about the machining process status in terms of workpiece quality and tool condition. On-line cutting force measurement is key for machining condition monitoring and machined surface quality assurance. This paper presents a novel instrumented working table with integrated polyvinylidene fluoride (PVDF) thin-film sensors, thus enabling the dynamic milling force measurement with compact structures. To achieve this, PVDF thin-film sensors are integrated into the working table to sense forces in different directions and the dedicated cutting force decoupling model is derived. A prototype instrumented working table is developed and validated. The validation demonstrates that profiles of the forces measured from the developed instrumented working table prototype and the dynamometer match well. Furthermore, the milling experiment results convey that the instrumented working table prototype could also identify the tool runout due to tool manufacturing or assembly errors, and the force signal spectrum analysis indicates that the developed working table can capture the tool passing frequency correctly, therefore, is suitable for the milling force measurement.

Inverse dynamic analysis of milling machining robot, application in calibration of cutting force

2019 ◽  
Vol 57 (6) ◽  
pp. 773 ◽  
Author(s):  
Hai Ha Thanh
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Inverse Dynamics ◽  
Milling Process ◽  
Machining Process ◽  
Empirical Formulas ◽  
Inverse Dynamic ◽  
Serial Manipulators ◽  
Machining Robot ◽  
Dynamics Problems

This article presents analysis of inverse dynamics of serial manipulators in milling process. Cutting forces and complicated motion involve to difficulties in solving dynamics problems of robots. In general, cutting forces are determined by using empirical formulas that lead to errors of cutting force values. Moreover, the cutting forces are changing and causing vibration during machining process. Errors of cutting force values affect to the accuracy of the dynamic model. This paper proposes an algorithm to compute the cutting forces based on the feedback values of the robot's motion.    

Investigation of Micro-Milling Force Based on Miniature Machine Tool

2010 ◽  
Vol 29-32 ◽  
pp. 1074-1078 ◽  
Author(s):  
Zi Yang Cao ◽  
Hua Li
Keyword(s):  
Machine Tool ◽  
Cutting Force ◽  
Milling Process ◽  
Machining Process ◽  
Micro Milling ◽  
Machining Parameters ◽  
Milling Force ◽  
Processing Efficiency ◽  
Side Milling ◽  
The Impact

Miniaturized components are increasingly in demand for various industries. Micro milling operations can fabricate miniaturized components with high relative accuracy. In micro milling process, the analysis of cutting force plays an important role in characterizing the machining process, as the tool wear and surface texture depending on the cutting force. In this paper, the orthogonal experiments under slot-milling and side-milling with typical micro three dimensional parts are done by the developed three-axis micro milling machine tool, and the micro milling force is measured and analyzed. In order to improve the processing efficiency and processing accuracy of micro milling process, the impact law of the spindle speed, axial cutting depth, feed per tooth and other parameters on cutting force is deeply studied, and the machining parameters is also optimized.

Optimization of turn-milling process in roughing and finishing regimes: Trade-off between productivity, cutting force and surface integrity

2021 ◽  
pp. 095440892199851
Author(s):  
Ebrahim Hosseini ◽  
Shafiqur Rehman ◽  
Ashkan Alimoradi
Keyword(s):  
Cutting Force ◽  
Desirability Function ◽  
Milling Process ◽  
Machining Process ◽  
Hybrid Machining ◽  
Trade Off ◽  
Hybrid Machining Process ◽  
Process Factors ◽  
Turn Milling ◽  
Selection Of

Turn-milling is a hybrid machining process which used benefits of interrupted cutting for proceeding of round bars. However, number of controllable parameters in the hybrid process is numerous that makes optimizing the process complicated. In the present study, an optimization work has been proposed to investigate the trade-off between production rate and cutting force in roughing regime as well surface roughness and tensile residual stress in finishing regime. Number of 43 experiments based on response surface methodology was designed and carried out to gather required data for development of quadratic empirical models. Then, the adequacy and importance of process factors were analyzed using analysis of variances. Finally, desirability function was used to optimize the process in rough and finish machining regimes. The obtained results showed that selection of eccentricity and cutter speed at their maximum working range can effectively enhance the quality characteristics in both the roughing and finishing regimes.

Milling Force Prediction for Circular Contour Machining

2014 ◽  
Vol 800-801 ◽  
pp. 243-248
Author(s):  
Kai Zhao ◽  
Zhan Qiang Liu
Keyword(s):  
Prediction Model ◽  
Milling Process ◽  
Machining Process ◽  
Curvature Radius ◽  
Force Model ◽  
Milling Force ◽  
Circular Contour ◽  
The Mean ◽  
Contour Machining ◽  
Matlab Programming

When machining the complex parts of aircraft engines, the milling force for the circular contour must be accurately predicted to reduce machining vibration. In this paper, the prediction model of the mean milling force per tooth during machining circular contour is developed. Firstly, the formulas of the entry angle, the exit angle and the equivalent feed per tooth are established through the analysis of circular contour milling process. Then, the equation of the mean milling force per tooth is deduced based on mechanistic force model during the circular contour machining process. Finally, the prediction model of mean milling force per tooth during machining circular contour is developed using MATLAB programming. The relationship between the milling force per tooth and surface curvature radius of the machined workpiece is also analyzed in this paper.

Contrast Research on Cutting Forces in 4-Axis and 5-Axis Blade Machining Process

2010 ◽  
Vol 142 ◽  
pp. 209-213
Author(s):  
Tong Wu ◽  
Can Zhao ◽  
Guang Bin Bu ◽  
Dun Wen Zuo
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Test Method ◽  
Machining Process ◽  
Paper Test ◽  
Nc Program ◽  
Blade Machining ◽  
The Difference

In this paper, test method was used to study the distribution of cutting force while blade machined with 4-axis and 5-axis NC program. The main difference between the two program was given. The difference of machining forms between 4-axis and 5-axis has led to their cutting forces distribution were different. The change of cutting force in 4-axis machining was large while the 5-axis machining was relatively stable. 5-axis cutting force had no impact comparing with 4-axis, which is more suitable for blade machining.

Erfahrungen mit alternativen Kraftmessungen/Experiences with alternative force measurements - Comparing sensor-integrated toolholders to traditional piezo-based measurement technology

2020 ◽  
Vol 110 (01-02) ◽  
pp. 24-31
Author(s):  
Patrick Georgi ◽  
Ssrah Eschelbacher ◽  
Thomas Stehle ◽  
Hans-Christian Möhring
Keyword(s):  
Cutting Force ◽  
Force Measurement ◽  
Milling Process ◽  
The Other ◽  
Strain Gauges ◽  
Measurement Technology ◽  
Optimal Parameters ◽  
Force Measurements ◽  
Measuring Systems ◽  
The One

Die Prozessüberwachung spielt in der Zerspanung eine immer wichtiger werdende Rolle. So können zum Beispiel mittels Zerspankraftmessungen ökonomisch optimierte Parameter in Zerspanprozessen gefunden werden, die zu einer Verbesserung der Auslastung von Werkzeug und Maschine führen. Des Weiteren kann über die Zerspankraft auf den aktuellen Verschleißzustand der Werkzeuge im Prozess sowie auf die jeweils erreichbare Bearbeitungsgenauigkeit zurückgeschlossen werden. Für Zerspankraftmessungen gibt es eine Vielzahl an zur Verfügung stehenden Kraftmesssystemen; zum einen traditionelle Messtechnik auf Basis von Piezosensoren zur Kraftmessung und zum anderen Kraftmesstechnik auf der Basis von Dehnmessstreifen (DMS). Dieser Beitrag untersucht die Kraftaufnahme bei Fräs- und Bohrprozessen, bei denen beide Kraftmesssysteme simultan eingesetzt wurden.   Process monitoring plays an increasingly important role in machining. For example, through cutting force measurements, it is possible to find economically optimal parameters in the milling process, which lead to an improvement in the utilization of the tool and the machine. Furthermore, the cutting force can be used to deduce the state of wear of the tools in the process. There are varieties of available force measuring systems for this purpose; on the one hand, traditional measuring technology based on piezo sensors for force measurement and the other force measuring technology based on strain gauges (strain gauges). This article examines the force absorption in milling and drilling processes where both force-measuring systems were used simultaneously.

scholarly journals Modified Mechanistic Model Based on Gaussian Process Adjusting Technique for Cutting Force Prediction in Micro-End Milling

2019 ◽  
Vol 2019 ◽  
pp. 1-12
Author(s):  
Xiaoping Liao ◽  
Zhenkun Zhang ◽  
Kai Chen ◽  
Kang Li ◽  
Junyan Ma ◽  
...  
Keyword(s):  
Gaussian Process ◽  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Mechanistic Model ◽  
Machining Process ◽  
Mechanistic Models ◽  
Machining Processes ◽  
Model Based ◽  
Micro End Milling

Micro-end milling is in common use of machining micro- and mesoscale products and is superior to other micro-machining processes in the manufacture of complex structures. Cutting force is the most direct factor reflecting the processing state, the change of which is related to the workpiece surface quality, tool wear and machine vibration, and so on, which indicates that it is important to analyze and predict cutting forces during machining process. In such problems, mechanistic models are frequently used for predicting machining forces and studying the effects of various process variables. However, these mechanistic models are derived based on various engineering assumptions and approximations (such as the slip-line field theory). As a result, the mechanistic models are generally less accurate. To accurately predict cutting forces, the paper proposes two modified mechanistic models, modified mechanistic models I and II. The modified mechanistic models are the integration of mathematical model based on Gaussian process (GP) adjustment model and mechanical model. Two different models have been validated on micro-end-milling experimental measurement. The mean absolute percentage errors of models I and II are 7.76% and 6.73%, respectively, while the original mechanistic model’s is 15.14%. It is obvious that the modified models are in better agreement with experiment. And model II performs better between the two modified mechanistic models.

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.

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