Modeling of cutting forces in helical milling by analysis of tool contact angle and respective depths of cut

Helical milling is used to generate holes, in which a tool attached to the rotating spindle traverses a helical trajectory, and the diameter of holes will be larger than that of the tool. Based on the principle of helical milling, this paper establishes analytical model of cutting forces. As the cutter travels on the helical path, intersection between the tool and the workpiece changes continuously, in which chip thickness and direction of the cutting forces will vary simultaneously. The cutting forces are not only direct proportional to the axial depth of cut, but also related to the rotational speed and orbital speed of the tool. Cutting experiment is conducted for the titanium alloy. The result shows that the simulated cutting force can be used to predict the change of cutting force under different conditions.

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Research on Dynamic Cutting Performance of High Speed Face Milling Cutter

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.375-376.663 ◽

2008 ◽

Vol 375-376 ◽

pp. 663-666

Author(s):

Min Li Zheng ◽

Bin Jiang ◽

Jia Liu ◽

Chong Yu He

Keyword(s):

Contact Angle ◽

Aluminum Alloy ◽

Frequency Spectrum ◽

Cutting Forces ◽

High Speed ◽

Cutting Speed ◽

Milling Process ◽

Face Milling ◽

Cutting Performance ◽

Milling Cutter

According to the characteristics of high speed face milling process, the models of dynamic cutting forces and frequency spectrum were established. By means of frequency spectrum analysis for dynamic cutting forces of high speed face milling cutter, the law of influence of cutter’s structure and parameters on dynamic cutting performance of cutter was acquired, high speed face milling cutter for machining aluminum alloy was developed, and evaluation for dynamic cutting performance of cutter was processed based on experiment. The results indicate that more teeth of cutter and greater cutting contact angle can make the energy more dispersible, higher cutting speed and greater rake of cutter can depress dynamic cutting forces, and improve effectively dynamic cutting performance of cutter. High speed face milling cutter with five teeth takes on better dynamic high speed cutting performance for machining aluminum alloy, as cutting contact angle exceeds ninety degrees but it is less than one hundred eighty degrees, and cutting speed exceeds 2260m/min.

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Research on the Relation between Cutting Parameters and Axial Cutting Force in Helical Milling Process

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.690-693.2480 ◽

2013 ◽

Vol 690-693 ◽

pp. 2480-2483 ◽

Cited By ~ 1

Author(s):

Hai Yan Wang ◽

Xu Da Qin

Keyword(s):

Regression Model ◽

Cutting Force ◽

Tool Life ◽

Cutting Forces ◽

Regression Models ◽

Cutting Parameters ◽

Milling Process ◽

Helical Milling ◽

Die Steel ◽

Axial Forces

The select of cutting parameters is not only directly related to the productivity, but also related to the change of cutting forces. Axial cutting force is too large to be ignored in the helical milling process. In this paper, the axial forces in helical milling of Cold die steel under different cutting parameters are measured, and the regression model of the axial force about the change of the cutting parameters is established, the influence of the cutting parameters on the axial cutting force is analyzed through the experimental results and the regression models respectively. The main purpose is to control axial cutting force and improve tool life in the cutting process.

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