An effective thread milling force prediction model considering instantaneous cutting thickness based on the cylindrical thread milling simplified to side milling process

2020 ◽  
Vol 110 (5-6) ◽  
pp. 1275-1283
Author(s):  
Zihua Hu ◽  
Changjiang Qin ◽  
Zhiwei Shi ◽  
Yiran Tang ◽  
Xudong Zhang ◽  
...  
Keyword(s):  
Prediction Model ◽  
Milling Process ◽  
Milling Force ◽  
Side Milling ◽  
Force Prediction ◽  
Thread Milling

Milling Force Prediction for Circular Contour Machining

2014 ◽  
Vol 800-801 ◽  
pp. 243-248
Author(s):  
Kai Zhao ◽  
Zhan Qiang Liu
Keyword(s):  
Prediction Model ◽  
Milling Process ◽  
Machining Process ◽  
Curvature Radius ◽  
Force Model ◽  
Milling Force ◽  
Circular Contour ◽  
The Mean ◽  
Contour Machining ◽  
Matlab Programming

When machining the complex parts of aircraft engines, the milling force for the circular contour must be accurately predicted to reduce machining vibration. In this paper, the prediction model of the mean milling force per tooth during machining circular contour is developed. Firstly, the formulas of the entry angle, the exit angle and the equivalent feed per tooth are established through the analysis of circular contour milling process. Then, the equation of the mean milling force per tooth is deduced based on mechanistic force model during the circular contour machining process. Finally, the prediction model of mean milling force per tooth during machining circular contour is developed using MATLAB programming. The relationship between the milling force per tooth and surface curvature radius of the machined workpiece is also analyzed in this paper.

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.

Analytical Prediction and Experimental Investigation of Burnishing Force in Rotary Ultrasonic Roller Burnishing Titanium Alloy Ti–6Al–4V

2020 ◽  
Vol 142 (3) ◽  
Author(s):  
Jian Zhao ◽  
Zhanqiang Liu ◽  
Bing Wang ◽  
Yukui Cai ◽  
Qinghua Song
Keyword(s):  
Titanium Alloy ◽  
Prediction Model ◽  
Milling Process ◽  
Analytical Prediction ◽  
Ultrasonic Power ◽  
Machined Surface ◽  
Softening Effect ◽  
Force Prediction ◽  
Contact Width ◽  
Acoustic Softening

Abstract Ultrasonic burnishing is usually applied to make machined surface modification. The acoustic softening effect caused by ultrasonic vibration is beneficial to the machining of difficult-to-cut materials. In the present work, a burnishing force prediction model was proposed for rotary ultrasonic burnishing of titanium alloy Ti–6Al–4V, whose surface had been machined with the face milling process. Firstly, the contact between the burnishing roller and one single milling mark was analyzed with plane strain assumption based on the Boussinesq–Flamant contact problem. Then, the effect of ultrasonic softening on the yield stress of Ti–6Al–4V was investigated. The critical contact width and contact load that the burnishing roller crushed on one single milling mark were examined to confirm the feasibility of the proposed ultrasonic burnishing force prediction model. The experimental verifications were carried out at various ultrasonic powers. The burnishing forces from experiment measurements were consistent with the calculated results from the proposed model. The mean deviations between theoretical and experimental results of the ultrasonic burnishing force were 10.4%, 12.2%, and 15.2%, corresponding to the ultrasonic power at the level of 41 W, 158 W, and 354 W, respectively.

Milling force prediction model based on transfer learning and neural network

2020 ◽  
Author(s):  
Juncheng Wang ◽  
Bin Zou ◽  
Mingfang Liu ◽  
Yishang Li ◽  
Hongjian Ding ◽  
...  
Keyword(s):  
Neural Network ◽  
Prediction Model ◽  
Transfer Learning ◽  
Milling Force ◽  
Force Prediction ◽  
Model Based

Experimental Study on Ball-End Milling of C/C Composite

2013 ◽  
Vol 650 ◽  
pp. 139-144
Author(s):  
Chen Wei Shan ◽  
Ying Zhao ◽  
Dong Peng Cui
Keyword(s):  
Prediction Model ◽  
High Speed ◽  
End Milling ◽  
Orthogonal Experiment ◽  
Carbon Matrix ◽  
Milling Process ◽  
Cutting Depth ◽  
Milling Force ◽  
Ball End Milling ◽  
Milling Forces

Along with the development of high speed machining technology, the ball end milling cutter’s application is more and more widely. An influence of four control parameters, namely feed, cutting depth, spindle speed and cutting width, on cutting forces is investigated. This paper focuses on experimental research of milling process of carbon fiber reinforced carbon matrix composite (C/C composite). The milling force prediction model for milling of composite using the carbide ball-end tools is built by orthogonal experiment. The experiment results show that : the reliability of the this prediction model is quite high, and the effect of milling speed on milling force is not very obvious, but the milling force increases with the increment of feed per tooth, milling depth and milling width. Using this information, a new prediction model for the milling forces is proposed that can be used for C/C composite milling.

scholarly journals Virtual milling force monitoring method based on in-process milling force prediction model to eliminate predetermination of cutting coefficients

Procedia CIRP ◽  
2018 ◽  
Vol 77 ◽  
pp. 22-25 ◽  
Author(s):  
Kazuki Kaneko ◽  
Isamu Nishida ◽  
Ryuta Sato ◽  
Keiichi Shirase
Keyword(s):  
Prediction Model ◽  
Milling Force ◽  
Monitoring Method ◽  
Force Prediction ◽  
Cutting Coefficients ◽  
Force Monitoring

Investigation of Micro-Milling Force Based on Miniature Machine Tool

2010 ◽  
Vol 29-32 ◽  
pp. 1074-1078 ◽  
Author(s):  
Zi Yang Cao ◽  
Hua Li
Keyword(s):  
Machine Tool ◽  
Cutting Force ◽  
Milling Process ◽  
Machining Process ◽  
Micro Milling ◽  
Machining Parameters ◽  
Milling Force ◽  
Processing Efficiency ◽  
Side Milling ◽  
The Impact

Miniaturized components are increasingly in demand for various industries. Micro milling operations can fabricate miniaturized components with high relative accuracy. In micro milling process, the analysis of cutting force plays an important role in characterizing the machining process, as the tool wear and surface texture depending on the cutting force. In this paper, the orthogonal experiments under slot-milling and side-milling with typical micro three dimensional parts are done by the developed three-axis micro milling machine tool, and the micro milling force is measured and analyzed. In order to improve the processing efficiency and processing accuracy of micro milling process, the impact law of the spindle speed, axial cutting depth, feed per tooth and other parameters on cutting force is deeply studied, and the machining parameters is also optimized.

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