A Study on Prediction of Milling Forces

2020 ◽  
pp. 86-93
Author(s):  
Do Duc Trung ◽  
Tran Ngoc Giang ◽  
Tran Thi Hong ◽  
Bui Thanh Danh ◽  
Vu Van Khoa ◽  
...  
Keyword(s):  
Milling Forces

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.

The Role of Cutter Eccentricity on Surface Finish and Milling Forces

2004 ◽  
Author(s):  
Tony L. Schmitz ◽  
Jeremiah Couey ◽  
Eric Marsh ◽  
Michael F. Tummond
Keyword(s):  
Surface Finish ◽  
Milling Machine ◽  
Time Domain Simulation ◽  
Machined Surface ◽  
Premature Failure ◽  
Series Of Experiments ◽  
Error Motion ◽  
Milling Forces ◽  
Chip Load

In this paper, the role of milling cutter eccentricity, commonly referred to as runout, is explored to determine its effects on surface topography and milling forces. This work is motivated by the observation that commercially-available cutter bodies often exhibit variation in the teeth/insert radial locations as a result of manufacturing issues. Consequently, the chip load on individual cutting teeth varies periodically, which can lead to premature failure of the cutting edges. Additionally, this chip load variation increases the roughness of machined surfaces. This research isolates the effect of runout on cutting forces and the machined surface finish in a series of experiments completed on a precision milling machine with 0.1 μm positioning repeatability and 0.02 μm spindle error motion. The runout is varied in a controlled fashion and results compared between experiment and a comprehensive time-domain simulation.

Generic modelling of milling forces for CAD/CAM applications

2004 ◽  
Vol 44 (1) ◽  
pp. 29-37 ◽  
Author(s):  
Mehdi Chérif ◽  
Hervé Thomas ◽  
Benoît Furet ◽  
Jean-Yves Hascoët
Keyword(s):  
Cad Cam ◽  
Milling Forces

Multi-Toothed Milling Force Model and Simulation for Form Milling the Gear of the Hypoid Gears

2011 ◽  
Vol 328-330 ◽  
pp. 90-95 ◽  
Author(s):  
Xin Jie Jia ◽  
Xiao Zhong Deng ◽  
Xiao Zhong Ren
Keyword(s):  
Face Milling ◽  
Force Model ◽  
Geometrical Theory ◽  
Hypoid Gear ◽  
Milling Force ◽  
Hypoid Gears ◽  
Model And Simulation ◽  
Simulation Results ◽  
Milling Forces ◽  
Milling Force Model

Prediction of the forces in milling hypoid gear was often needed in order to establish automation and optimization of the tooth-milling processes. Based on the geometrical theory of the format face-milling, the multi-toothed milling forces theoretical model for form milling the gear of the hypoid gears is presented, the milling force factors were calibrated via single factor experiments and the simulation programs were prepared. Experiments were carried out to verify the availability of the multi-toothed dynamic milling force model, the experimental results is consistent with the simulation results.

A Simulation Study on the End Milling Operation with Multiple Process Steps of Aeronautical Frame Monolithic Components

2011 ◽  
Vol 66-68 ◽  
pp. 569-572
Author(s):  
Hai Chao Ye ◽  
Guo Hua Qin ◽  
Cong Kang Wang ◽  
Dong Lu
Keyword(s):  
End Milling ◽  
Machining Process ◽  
Deformation Analysis ◽  
Tool Paths ◽  
Milling Operation ◽  
Multiple Process ◽  
Monolithic Components ◽  
Milling Forces ◽  
The Given

Machining deformation has always been a bottleneck issue in the manufacturing field of aeronautical monolithic components. On the base of finite element method, the effect of the process steps and tool paths on the workpiece stiffness and the redistribution of residual stress in the machining process of aeronautical frame monolithic component was investigated under the given fixturing scheme. Thus, the prediction of the workpiece deformation can be carried out in reason. The proposed simulation approach to deformation analysis can be used to observe the true characteristic of milling forces and machining deformations. Therefore, the proposed method can supply the theoretical basis for the determination of the optimal process parameters.

A HIGHER FIDELITY MODELING OF THE CUTTING EDGE OF BALL-END MILLING TOOL

2011 ◽  
Vol 10 (01) ◽  
pp. 101-108 ◽  
Author(s):  
XIULIN SUI ◽  
IMRE HORVATH ◽  
JIATAI ZHANG ◽  
PING ZHANG
Keyword(s):  
End Milling ◽  
Milling Process ◽  
Cutting Edge ◽  
Ball End Milling ◽  
Machining Conditions ◽  
Milling Tool ◽  
Efficient Planning ◽  
Pilot Implementation ◽  
Physical Changes ◽  
Milling Forces

Ball-end milling tools have been widely used in machining of complex freeform surfaces. The precision and efficiency of ball-end milling process can be improved by an accurate modeling of the tools, the tools' paths and the machining conditions. However, only rough geometric models have been applied so far, which do not consider the machining conditions and the physical changes. To achieve the best results, an accurate modeling of the cutting edge and the physical behavior of the entire cutter is needed. This paper proposes an articulated model that enumerates both the geometric characteristics and the physical effects acting on the cutting edge-segment of a ball-end milling cutter. The model considers the deformations caused by the milling forces, vibration, spindle eccentricity, together with thermal deformation and wear of the cutter. The mathematical description of the behavior has been transferred into a computational model. The pilot implementation has been tested in a practical application. The first findings show that the proposed theoretical model and implementation provide sufficiently precise information about the behavior of the cutter in virtual simulations; hence it can be the basis of a fully fledged and more efficient planning of milling processes.

scholarly journals Workpiece Pose Optimization for Milling with Flexible-Joint Robots to Improve Quasi-Static Performance

2019 ◽  
Vol 9 (6) ◽  
pp. 1044 ◽  
Author(s):  
Haojie Qin ◽  
Yuwen Li ◽  
Xiong Xiong
Keyword(s):  
Cutting Forces ◽  
Industrial Robots ◽  
Robot Dynamics ◽  
Optimization Approach ◽  
Dynamics Model ◽  
Milling Force ◽  
Tool Offset ◽  
Static Performance ◽  
Pose Optimization ◽  
Milling Forces

Although industrial robots are widely used in production automation, their applications in machining have been limited because of the structural vibrations induced by periodic cutting forces. Since the dynamic characteristics of an industrial robot depends on its configuration, the responses of the robot structure to the cutting forces are affected by how the workpiece is placed within the workspace of the robot. This paper presents a method for workpiece pose optimization for a robotic milling system to improve the quasi-static performance during machining. Since the milling forces are time-varying due to the characteristics of the multi-tooth and discontinuity of milling, these forces can excite vibrations inside the robot structure. To address this issue, a structural dynamics model is established for industrial robots, considering their joint flexibility, and a milling force formulation is incorporated into the robot dynamics model to investigate the forced vibrations of the flexible joints. Then, the quasi-static performance of the robotic machining system is evaluated by the vibration-induced offset of the cutter tool that is mounted on the end-effector. Finally, an optimization approach is given for the workpiece pose to minimize the cutter tool offset under the periodic milling force. A numerical simulation demonstrates that the optimal workpiece pose can significantly reduce the overall tool offset during machining and can lower the variation of the tool offset along the milling path.

scholarly journals Sustainable Milling of Ti-6Al-4V: Investigating the Effects of Milling Orientation, Cutter′s Helix Angle, and Type of Cryogenic Coolant

Metals ◽  
2020 ◽  
Vol 10 (2) ◽  
pp. 258 ◽  
Author(s):  
Asif Iqbal ◽  
Hazwani Suhaimi ◽  
Wei Zhao ◽  
Muhammad Jamil ◽  
Malik M Nauman ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
Energy Consumption ◽  
Tool Wear ◽  
Cutting Speed ◽  
Helix Angle ◽  
Work Surface ◽  
Process Cost ◽  
Mechanical Properties And Corrosion ◽  
Milling Forces

Ti-6Al-4V, the most commonly used alloy of titanium, possesses excellent mechanical properties and corrosion resistance, which is the prime reason for the continual rise in its industrial demand worldwide. The extraordinary mechanical properties of the alloy are viewed as a hindrance when it comes to its shaping processes, and the process of milling is no exception to it. The generation of intense heat flux around the cutting zones is an established reason of poor machinability of the alloy and unacceptably low sustainability of its machining. The work presented in this paper attempts to enhance sustainability of milling Ti-6Al-4V by investigating the effects of milling orientation, cutter’s helix angle, cutting speed, and the type of cryogenic coolant and lubricant on the sustainability measures, such as tool damage, cutting energy consumption, process cost, milling forces, and work surface roughness. It was found that micro-lubrication is more effective than the two commonly used cryogenic coolants (carbon dioxide snow and liquid nitrogen) in reducing tool wear, work surface roughness, process cost, and energy consumption. Furthermore, down-milling enormously outperformed up-milling with respect to tool wear, work surface quality, and process cost. Likewise, the high levels of cutter’s helix angle and cutting speed also proved to be beneficial for milling sustainability.

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