Modelling of cutting forces and researching calibration method in helical milling

Many pieces in structure of a dynamometer may negatively affect the accuracy of the measurements since each piece may display a different strain and stress depending on its material and construction. A one piece dynamometer has been designed to eliminate these negative effects and to facilitate reliable force measurements. A dynamometer that its dimensions were confirmed following strength calculations was manufactured and calibrated in two different ways. The first one was multipoint calibration method in which certain loads were applied to the dynamometer and strain values corresponding to these loads were matched. The second calibration method was implemented using Kistler dynamometer that its results are accepted to be accurate by everyone and it was based on equivalency of force values resulted from work piece processing and force values resulting from machining work pieces with the same parameters to the manufactured dynamometer. The manufactured dynamometer was capable of measuring cutting forces and feeding forces.

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Modelling, simulation and experimental investigation of cutting forces during helical milling operations

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-012-3951-4 ◽

2012 ◽

Vol 63 (9-12) ◽

pp. 839-850 ◽

Cited By ~ 36

Author(s):

Changyi Liu ◽

Gui Wang ◽

Matthew S. Dargusch

Keyword(s):

Experimental Investigation ◽

Cutting Forces ◽

Helical Milling ◽

Milling Operations ◽

Modelling Simulation

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

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-013-4837-9 ◽

2013 ◽

Vol 68 (9-12) ◽

pp. 2311-2319 ◽

Cited By ~ 14

Author(s):

C. E. H. Ventura ◽

A. Hassui

Keyword(s):

Contact Angle ◽

Cutting Forces ◽

Helical Milling

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Analysis of Cutting Forces in Helical Milling Process

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.215.9 ◽

2011 ◽

Vol 215 ◽

pp. 9-13 ◽

Cited By ~ 2

Author(s):

H.Y. Wang ◽

Xu Da Qin ◽

Qi Wang

Keyword(s):

Titanium Alloy ◽

Cutting Force ◽

Rotational Speed ◽

Cutting Forces ◽

Chip Thickness ◽

Milling Process ◽

Helical Milling ◽

Depth Of Cut ◽

Cutting Experiment ◽

Tool Cutting

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 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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