A cutting force model considering influence of radius of curvature for sculptured surface machining

2010 ◽  
Vol 54 (5-8) ◽  
pp. 821-835 ◽  
Author(s):  
Qingyuan Cao ◽  
Deyi Xue ◽  
Jun Zhao ◽  
Yueen Li
Keyword(s):  
Cutting Force ◽  
Radius Of Curvature ◽  
Force Model ◽  
Sculptured Surface ◽  
Cutting Force Model ◽  
Surface Machining ◽  
Sculptured Surface Machining

A 3-D Closed-Form Cutting Force Model for End Milling With Application to Sculptured Surface Milling

1999 ◽  
Author(s):  
T. S. Lee ◽  
R. Farahati ◽  
Y. J. Lin
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Free Form ◽  
Depth Of Cut ◽  
Force Model ◽  
Sculptured Surface ◽  
Cutting Force Model ◽  
Estimation Scheme ◽  
Simulation Results ◽  
Axial Depth

Abstract A comprehensive, 3D mathematical model of desired/optimal cutting force for end milling of free-form surfaces is proposed in this paper. The closed-form predictive model is developed based on a perceptive cutting approach resulting in a cutting force model having a comprehensive set of essential cutting parameters. In particular, the normal rake angle usually missing in most existing models of the same sort is included in the developed model. The model also enables quantitative analyses of the effect of any parameters on the cutting performance of the tool, providing a guideline to improving the tool performance. Since the axial depth of cut varies with time when milling sculptured surface parts, an innovative axial depth of cut estimation scheme is proposed for the generation of 3-D cutting forces. This estimation scheme improves the practicality of most existing predictive cutting force model for milling in which the major attention has been focused on planar milling surface generation. In addition, the proposed model takes the rake surface on the flute of mills as an osculating plane to yield 3-D cutting force expressions with only two steps. This approach greatly reduces the time-consuming mathematical work normally required for obtaining the cutting force expressions. A series of milling simulations for machining free-form parts under scenario cutting conditions have been performed to verify the effectiveness of the proposed cutting force model. The simulation results demonstrate accurate estimating capability of the proposed method for the axial depth of cut estimation. The cutting force responses from the simulation exhibit the same trends as what can be obtained using the empirical mechanic’s model referenced in the literature. Finally, through the simulation results it is also learned that designing a tool with a combination of different helix angles having cutting force signatures similar to that of the single helix angle counterparts is particularly advantageous.

scholarly journals A Prediction Model of Cutting Force about Ball End Milling for Sculptured Surface

2020 ◽  
Vol 2020 ◽  
pp. 1-15
Author(s):  
Wenping Mou ◽  
Shaowei Zhu ◽  
Menghao Zhu ◽  
Lei Han ◽  
Lei Jiang
Keyword(s):  
Prediction Model ◽  
Coordinate System ◽  
Cutting Force ◽  
Sculptured Surface ◽  
Machining Parameters ◽  
End Mill ◽  
Ball End Mill ◽  
Surface Machining ◽  
Sculptured Surface Machining ◽  
Tool Posture

Cutting force prediction is very important to optimize machining parameters and monitor machining state. In order to predict cutting force of sculptured surface machining with ball end mill accurately, tool posture, cutting edge, contact state between cutter, and workpiece are studied. Firstly, an instantaneous motion model of ball end mill for sculptured surface is established. The instantaneous milling coordinate system and instantaneous tool coordinate system are defined to describe the position and orientation of tool, and the transformation matrix between coordinate systems is derived. Secondly, by solving three boundaries around engagement of cutter and workpiece, a cutter-workpiece engagement model related to tool posture, milling parameters, and tool path is established. It has good adaptability to the variable tool axis relative to the machining surface. Finally, an algorithm of thickness about an instantaneous undeformed chip is researched, and a prediction model of cutting force is realized with microelement cutting theory. Also, the model is suitable for sculptured surface machining with arbitrary tool posture and feed direction. The accuracy of the proposed prediction model was verified by a series of experiments.

3D Cutting Force Model of a Stinger PDC Cutter: Considering Confining Pressure and the Thermal Stress

2021 ◽  
Author(s):  
Chao Xiong ◽  
Zhongwei Huang ◽  
Huaizhong Shi ◽  
Ruiyue Yang ◽  
Xianwei Dai ◽  
...  
Keyword(s):  
Thermal Stress ◽  
Cutting Force ◽  
Confining Pressure ◽  
Force Model ◽  
Cutting Force Model

Automatic Planning for 5-Axis Sculptured Surface Machining

1994 ◽  
Author(s):  
Yuan-Shin Lee ◽  
Tien-Chien Chang
Keyword(s):  
Sculptured Surface ◽  
Sculptured Surfaces ◽  
Design Modification ◽  
Surface Machining ◽  
Sculptured Surface Machining ◽  
Cutter Path ◽  
Automatic Planning ◽  
Five Axis ◽  
Five Axes ◽  
Complete Operation

Abstract In modern product design, sculptured surfaces are commonly used for functional and artistic shape design. Design of sculptured surfaces is evolutionary, consisting primarily of incremental changes to existing part surfaces. Manual operation planning for sculptured surface machining is known to be error-prone and inefficient, which requires considerable checking, verification, and rework. Five-axis machining has higher productivity and better machining quality than 3-axis machining. However, the programming for 5-axis machining is more difficult due to the complex simultaneous cutter movements along the machine’s five axes. This paper presents a systematic methodology to generate operation plans for 5-axis sculptured surface machining. A complete operation plan and the error-free cutter path can be automatically generated from the CAD part design. To achieve design for manufacturing of sculptured surface products, the machining unfeasibility information can be fed back to the designer for further design modification. Results of computer implementation and testing examples are also presented.

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