Optimization of cutter posture based on cutting force prediction for five-axis machining with ball-end cutters

2015 ◽  
Vol 78 (5-8) ◽  
pp. 1289-1303 ◽  
Author(s):  
L. Geng ◽  
P. L. Liu ◽  
K. Liu
Keyword(s):  
Cutting Force ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
Five Axis

Dynamics and Stability Prediction of Five-Axis Flat-End Milling

2017 ◽  
Vol 139 (6) ◽  
Author(s):  
YaoAn Lu ◽  
Ye Ding ◽  
LiMin Zhu
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Stability Prediction ◽  
Tool Orientation ◽  
Cutting Force Prediction ◽  
Vector Method ◽  
Force Prediction ◽  
Flat End Milling ◽  
The Stability ◽  
Five Axis

The tool orientation of a flat-end cutter, determined by the lead and tilt angles of the cutter, can be optimized to increase the machining strip width. However, few studies focus on the effects of tool orientation on the five-axis milling process stability with flat-end cutters. Stability prediction starts with cutting force prediction, and the cutting force prediction is affected by the cutter-workpiece engagement (CWE). The engagement geometries occur between the flat-end cutter and the in-process workpiece (IPW) are complicated in five-axis milling, making the stability analysis for five-axis flat-end milling difficult. The robust discrete vector method (DVM) is adopted to identify the CWE for flat-end millings, and it can be extended to apply to general cutter millings. The milling system is then modeled as a two-degrees-of-freedom spring-mass-damper system with the predicted cutting forces. Thereafter, a general formulation for the dynamic milling system is developed considering the regenerative effect and the mode coupling effect simultaneously. Finally, an enhanced numerical integration method (NIM) is developed to predict the stability limits in flat-end milling with different tool orientations. Effectiveness of the strategy is validated by conducting experiments on five-axis flat-end milling.

scholarly journals Cutting Force Prediction Models by FEA and RSM When Machining X56 Steel with Single Diamond Grit

Micromachines ◽  
2021 ◽  
Vol 12 (3) ◽  
pp. 326
Author(s):  
Lan Zhang ◽  
Xianbin Sha ◽  
Ming Liu ◽  
Liquan Wang ◽  
Yongyin Pang
Keyword(s):  
Cutting Force ◽  
Coefficient Of Friction ◽  
High Speed ◽  
Prediction Models ◽  
Pipeline Steel ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
Diamond Wire Saw

In the field of underwater emergency maintenance, submarine pipeline cutting is generally performed by a diamond wire saw. The process, in essence, involves diamond grits distributed on the surface of the beads cutting X56 pipeline steel bit by bit at high speed. To find the effect of the different parameters (cutting speed, coefficient of friction and depth of cut) on cutting force, the finite element (FEA) method and response surface method (RSM) were adopted to obtain cutting force prediction models. The former was based on 64 simulations; the latter was designed according to DoE (Design of Experiments). Confirmation experiments were executed to validate the regression models. The results indicate that most of the prediction errors were within 10%, which were acceptable in engineering. Based on variance analyses of the RSM models, it could be concluded that the depth of the cut played the most important role in determining the cutting force and coefficient the of friction was less influential. Despite making little direct contribution to the cutting force, the cutting speed is not supposed to be high for reducing the coefficient of friction. The cutting force models are instructive in manufacturing the diamond beads by determining the protrusion height of the diamond grits and the future planning of the cutting parameters.

Milling Force Prediction Model for Five-Axis Machining of Freeform Surface Considering Mesoscopic Size Effect

2021 ◽  
Vol 143 (9) ◽  
Author(s):  
Minglong Guo ◽  
Zhaocheng Wei ◽  
Minjie Wang ◽  
Jia Wang ◽  
Shengxian Liu
Keyword(s):  
Dislocation Density ◽  
Size Effect ◽  
Prediction Model ◽  
Cutting Force ◽  
Freeform Surface ◽  
End Mill ◽  
Ball End Mill ◽  
Milling Force ◽  
Force Prediction ◽  
Five Axis

Abstract The core parts with the characteristic of freeform surface are widely used in the major equipment of various fields. Cutting force is the most important physical quantity in the five-axis CNC machining process of core parts. Not only in micro-milling, but also in macro-milling, there is also an obvious size effect, especially in medium- and high-speed milling, which is frequently ignored. In this paper, the milling force prediction model for five-axis machining of a freeform surface with a ball-end mill considering the mesoscopic size effect is established. Based on the characteristics of cutting thickness in macro-milling, a new dislocation density correction form is proposed, and a new experiment is designed to identify the dislocation density correction coefficient. Therefore, the shear stress calculated in this paper not only reflects the cutting dynamic mechanical characteristics but also considers the mesoscopic size effect. A linear function is proposed to describe the relationship between friction coefficient and cutting speed, cutter rake angle, and cutting thickness. Considering cutter run-out, the micro-element cutting force in the shear zone and plough zone are analyzed. The cutting geometry contact between the freeform surface and the ball-end mill is analyzed analytically by the space limitation method. Finally, the total milling force is obtained by summing all the force vectors of cutting edge micro-elements within the in-cut cutting edge. In the five-axis machining experiment of freeform surface, the theoretically predicted results of milling forces are in good agreement with the measured results in trend and amplitude.

Analysis of Cutting Force in Elastomer End-Milling

2017 ◽  
Vol 11 (6) ◽  
pp. 958-963
Author(s):  
Koji Teramoto ◽  
◽  
Takahiro Kunishima ◽  
Hiroki Matsumoto
Keyword(s):  
Parameter Identification ◽  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Process Models ◽  
Force Model ◽  
Cutting Force Model ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
The Stability

Elastomer end-milling is attracting attention for its role in the small-lot production of elastomeric parts. In order to apply end-milling to the production of elastomeric parts, it is important that the workpiece be held stably to avoid deformation. To evaluate the stability of workholding, it is necessary to predict cutting forces in elastomer end-milling. Cutting force prediction for metal workpiece end-milling has been investigated for many years, and many process models for end-milling have been proposed. However, the applicability of these models to elastomer end-milling has not been discussed. In this paper, the characteristics of the cutting force in elastomer end-milling are evaluated experimentally. A standard cutting force model and its parameter identification method are introduced. By using this cutting force model, measured cutting forces are compared against the calculated results. The comparison makes it clear that the standard cutting force model for metal end-milling can be applied to down milling for a rough evaluation.

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