A novel six-state cutting force model for drilling-countersinking machining process of CFRP-Al stacks

A new cutting force model of ball-end mill with double effect is developed through analysing the machining process by using differential geometry. The cutting force model is needed to be revised for the component force in Z direction because of the offset to the actual results. The cutting force and the ball-end milling force coefficients can be given with numerical method. A feedrate optimization strategy is also proposed based on the developed cutting force model and tested effectively.

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Calibration of a Milling Force Model Using Feed and Spindle Power Sensors

ASME 2008 International Manufacturing Science and Engineering Conference, Volume 2 ◽

10.1115/msec_icmp2008-72315 ◽

2008 ◽

Cited By ~ 1

Author(s):

Bryan Javorek ◽

Barry K. Fussell ◽

Robert B. Jerard

Keyword(s):

Cutting Force ◽

Cutting Forces ◽

End Milling ◽

Machining Process ◽

Force Model ◽

Cutting Force Model ◽

Drive Power ◽

Average Force ◽

Force Monitoring ◽

Milling Force Model

Changes in cutting forces during a milling operation can be associated with tool wear and breakage. Accurate monitoring of these cutting forces is an important step towards the automation of the machining process. However, direct force sensors, such as dynamometers, are not practical for industry application due to high costs, unwanted compliance, and workspace limitations. This paper describes a method in which power sensors on the feed and spindle motors are used to generate coefficients for a cutting force model. The resulting model accurately predicts the X and Y cutting forces observed in several simple end-milling tests, and should be capable of estimating both the peak and average force for a given cut geometry. In this work, a dynamometer is used to calibrate the feed drive power sensor and to measure experimental cutting forces for verification of the cutting force model. Measurement of the average x-axis cutting forces is currently presented as an off-line procedure performed on a sacrificial block of material. The potential development of a continuous, real-time force monitoring system is discussed.

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Effect of Lubrication Conditions to the Cutting Force Coefficients in Machining Process

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.1115.55 ◽

2015 ◽

Vol 1115 ◽

pp. 55-58

Author(s):

Wan Mohd Azlan Nowalid ◽

Muhammad Adib Shaharun ◽

Ahmad Razlan Yusoff

Keyword(s):

Cutting Force ◽

Metal Cutting ◽

Machining Process ◽

Force Model ◽

Cutting Force Model ◽

Cutting Force Coefficients ◽

Milling Force ◽

Force Coefficients ◽

Milling Forces ◽

Lubrication Conditions

The cutting force is the main important factor contributing the machined work piece surface and in determining the acceptable cutting parameters for high productivity in metal cutting industries. The prediction of cutting force coefficients of materials were calculated from the average cutting force model contributing to the constants of cutting force coefficients. In this study, experimental investigation is conducted to determine the cutting force coefficients in the average cutting force model, by identifying cutting force coefficients with different lubrication conditions such as dry, flood and minimal lubrication conditions and cutting speeds. A series of slot milling experiments are measured the milling forces by fixing the spindle speeds and radial/axial depths of cutting and linearly varying the feed per tooth. Using linearly fitting the experimental data, the tangential and radial milling force coefficients are then computed. The achieved results showed that the changing of spindle speed and different lubrication conditions affecting the milling force coefficient.

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The Influence of Valve Seats Machining Process on Roundness Error

Volume 1: Advanced Energy Systems; Advanced and Digital Manufacturing; Advanced Materials; Aerospace ◽

10.1115/esda2008-59060 ◽

2008 ◽

Cited By ~ 1

Author(s):

Bartosz Powałka ◽

Reuven Katz

Keyword(s):

Cutting Force ◽

Model Development ◽

Machining Process ◽

Force Model ◽

Cutting Force Model ◽

Valve Seat ◽

Roundness Error ◽

Machining Force ◽

Tool Dynamics

This paper presents a methodology of valve seat machining force model development. A cutting force model coefficients are calibrated without the need of performing separate cutting tests for the blades of the valve seat tool. The developed cutting force model is validated using results of valve seat machining when the misalignement of the tool and workpiece axes was introduced. Also the model for the prediction of the roundess error that employs machine tool dynamics represented by frequency response function and cutting force model is proposed. Prediction quality of the roundness error model is compared to the CMM profile measurements.

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Comprehensive Dynamic Cutting Force Model and Its Application to Wave-Removing Processes

Journal of Engineering for Industry ◽

10.1115/1.3187864 ◽

1988 ◽

Vol 110 (2) ◽

pp. 153-161 ◽

Cited By ~ 16

Author(s):

D. W. Wu

Keyword(s):

Cutting Force ◽

Machining Process ◽

Plastic Deformation Zone ◽

Force Model ◽

Cutting Force Model ◽

Dynamic Cutting Force ◽

Theoretical Predictions ◽

Force Variation ◽

The Mean ◽

Good Agreement

A new concept is taken to develop a comprehensive cutting force model for analyzing the dynamic behavior of the machining process. The model is derived based on the principles of the cutting mechanics, and takes into account the fluctuation of the mean factional coefficient on the tool-chip interface as well as the variations of the normal hydrostatic pressure distribution and the shear flow stress along the primary plastic deformation zone. The model has been tested through computer simulation for orthogonal wave-removing processes by reference to an existing experimental evidence. The result indicates a generally good agreement with the theoretical predictions except that the amplitude of the force variation in the feeding direction appears to be underestimated. An explanation is also given.

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Cutting force prediction considering force-deflection coupling in five-axis milling with fillet-end cutter

10.21203/rs.3.rs-766959/v1 ◽

2021 ◽

Author(s):

Xianyin Duan ◽

Lantao Li ◽

Chen Chen ◽

Sheng Yu ◽

Zerun Zhu ◽

...

Keyword(s):

Cutting Force ◽

Tilt Angle ◽

Prediction Models ◽

Machining Process ◽

Machining Accuracy ◽

Force Model ◽

Cutting Force Model ◽

Lead Angle ◽

Cutter Deflection ◽

Five Axis

Abstract With the increasing demand for higher quality and performance of equipment and assembly in aerospace, shipbuilding, medical and other fields, the machining accuracy of parts is facing higher requirements. It is particularly important to predict the cutting force accurately, which is the main physical quantity in the machining process and basis of process inspection and quality control. In this paper, the cutting force model in five-axis milling with fillet-end cutter is proposed, which reveals the law of force-deflection coupling. Firstly, the initial cutter deflection model induced by the ideal cutting force ignoring the effect of deflection is built based on analysis of the geometric characteristics of fillet-end cutter. Then the undeformed chip thickness model is educed considering the cutter posture and cutter deflection. Further, the iterative method is utilized to resolve the coupling relationship between cutter deflection and cutting force. Finally, the cutting force model under force-deflection coupling is established for achieving more accurate prediction. To verify the effectiveness of the proposed cutting force model, the milling experiment is carried out on a five-axis milling center. The measured cutting force values are utilized to inspect the accuracy of prediction models considering and not considering force-deflection coupling respectively. The results show that the proposed method could improve the prediction accuracy of cutting force, which show the effectiveness of taking force-deflection coupling law into consideration clearly. The influence of cutter posture on cutting force is analyzed using the proposed cutting force model. The cutting force decreases with the increasing of lead angle or tilt angle, and the influence of tilt angle is greater than that of lead angle under experimental conditions of five-axis milling using the set process parameters.

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