Prediction of instantaneous milling force taking runout into account in peripheral milling of curved surface

2015 ◽  
Vol 79 (1-4) ◽  
pp. 49-56 ◽  
Author(s):  
Hongyan Hao ◽  
Baosheng Wang ◽  
Wencheng Tang
Keyword(s):  
Curved Surface ◽  
Peripheral Milling ◽  
Milling Force

Dynamic Force Identification in Peripheral Milling Based on CGLS Using Filtered Acceleration Signals and Averaged Transfer Functions

2019 ◽  
Vol 141 (6) ◽  
Author(s):  
Chenxi Wang ◽  
Xingwu Zhang ◽  
Baijie Qiao ◽  
Hongrui Cao ◽  
Xuefeng Chen
Keyword(s):  
Time Domain ◽  
Transfer Functions ◽  
Milling Process ◽  
Dynamic Force ◽  
Band Pass Filter ◽  
Peripheral Milling ◽  
Milling Force ◽  
Force Identification ◽  
Milling Forces ◽  
Acceleration Signals

Dynamic milling forces have been widely used to monitor the condition of the milling process. However, it is very difficult to measure milling forces directly in operation, particularly in the industrial scene. In this paper, a dynamic force identification method in time domain, conjugate gradient least square (CGLS), is employed for reconstructing the time history of milling forces using acceleration signals in the peripheral milling process. CGLS is adopted for force identification because of its high accuracy and efficiency, which handles the ill-conditioned matrix well. In the milling process, the tool with high-speed rotation has different transfer functions between tool nose and accelerometers at different angular positions. Based on this fact, the averaged transfer functions are employed to reduce the error amplification of regularization processing for milling force identification. Moreover, in order to eliminate the effect of idling and high-frequency components on identification accuracy, the Butterworth band-pass filter is adopted for acceleration signals preprocessing. Finally, the proposed method is validated by milling tests under different cutting parameters. Experimental results demonstrate that the identified and measured milling forces are in good agreement on the whole time domain, which verifies the effectiveness and generalization of the indirect method for milling force measuring. In addition, the Tikhonov regularization method is also implemented for comparison, which shows that CGLS has higher accuracy and efficiency.

Modeling Methodology of Flexible Milling Force for Thin-Walled Component on High Speed Peripheral Milling Processing System

2015 ◽  
Vol 799-800 ◽  
pp. 272-276
Author(s):  
Li Zhang ◽  
Wei Guo Gao ◽  
Da Wei Zhang
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Processing System ◽  
Peripheral Milling ◽  
Milling Force ◽  
Modeling Methodology ◽  
Thin Walled ◽  
The Relationship ◽  
Main Factor ◽  
Normal Deflection

This study has developed a model in order to show the relationship between deflection of the low-rigidity processing system such like thin-walled component and the flexible milling force. The new model takes the deflection of cutter-workpiece system into account. The cutting force is analyzed simulatively by utilizing modified Newton–Raphson iterative algorithm. The simulative results show that the total normal deflection of workpiece–cutter system is the main factor affecting the change of cutting force.

scholarly journals Milling force identification from acceleration signals using regularization method based on TSVD in peripheral milling

Procedia CIRP ◽  
2018 ◽  
Vol 77 ◽  
pp. 18-21 ◽  
Author(s):  
Chenxi Wang ◽  
Xingwu Zhang ◽  
Baijie Qiao ◽  
Xuefeng Chen ◽  
Hongrui Cao
Keyword(s):  
Regularization Method ◽  
Peripheral Milling ◽  
Milling Force ◽  
Force Identification ◽  
Acceleration Signals

scholarly journals Location-Dependent Prediction of Dynamic Stability Limit for Peripheral Milling of Surfaces with Variable Curvatures

2018 ◽  
Vol 2018 ◽  
pp. 1-10
Author(s):  
Baosheng Wang ◽  
Hongyan Hao ◽  
Mulan Wang ◽  
Junming Hou
Keyword(s):  
Time Domain ◽  
Stability Limit ◽  
Complex Surface ◽  
Cutting Parameters ◽  
System Dynamic Model ◽  
Cutting Depth ◽  
Peripheral Milling ◽  
Milling Force ◽  
The Stability ◽  
The Time Domain

The stability limit may change with the cutter’s location due to effect of curvature during the milling of a complex surface. The method for calculating the actual radial cutting depth is presented by accounting for the effects of curvature on the actual cutting parameters. The computed radial cutting depth is in turn used to determine the entrance/exit angles. Moreover, a milling system dynamic model is established based on the instantaneous milling force coefficients, and the stability limit is determined by means of the time-domain semidiscretization method. In addition, a location-dependent method for predicting the stability associated with the peripheral milling of a complex surface is put forward and simulation is carried out to generate a stability limit diagram. The effectiveness of the proposed method is verified through milling tests.

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