Modeling and estimation of cutting forces in ball helical milling process

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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Prediction of cutting forces in helical milling process

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-011-3435-y ◽

2011 ◽

Vol 58 (9-12) ◽

pp. 849-859 ◽

Cited By ~ 55

Author(s):

Haiyan Wang ◽

Xuda Qin ◽

Chengzu Ren ◽

Qi Wang

Keyword(s):

Cutting Forces ◽

Milling Process ◽

Helical Milling

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Multivariate robust modeling and optimization of cutting forces of the helical milling process of the aluminum alloy Al 7075

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-017-1398-3 ◽

2017 ◽

Vol 95 (5-8) ◽

pp. 2691-2715 ◽

Cited By ~ 6

Author(s):

Robson Bruno Dutra Pereira ◽

Rodrigo Reis Leite ◽

Aline Cunha Alvim ◽

Anderson Paulo de Paiva ◽

Pedro Paulo Balestrassi ◽

...

Keyword(s):

Aluminum Alloy ◽

Cutting Forces ◽

Milling Process ◽

Helical Milling ◽

Robust Modeling ◽

Modeling And Optimization ◽

Al 7075

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Modeling of cutting forces in helical milling of unidirectional CFRP considering carbon fiber fracture

Journal of Manufacturing Processes ◽

10.1016/j.jmapro.2021.06.058 ◽

2021 ◽

Vol 68 ◽

pp. 1495-1508

Author(s):

Shun Zhang ◽

Feng Jiao ◽

Xue Wang ◽

Ying Niu

Keyword(s):

Carbon Fiber ◽

Cutting Forces ◽

Helical Milling ◽

Fiber Fracture

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Effect of thermomechanical densification of pine wood (Pinus sylvestris L.) on cutting forces and roughness during milling

Annals of WULS, Forestry and Wood Technology ◽

10.5604/01.3001.0015.2330 ◽

2021 ◽

Vol 113 ◽

pp. 36-42

Author(s):

Barbara Białowąs ◽

Karol Szymanowski

Keyword(s):

Mechanical Properties ◽

Surface Roughness ◽

Statistical Analysis ◽

Pinus Sylvestris ◽

Cutting Forces ◽

Physical And Mechanical Properties ◽

Milling Process ◽

Pine Wood ◽

Roughness Index ◽

Modified Wood

Effect of thermomechanical densification of pine wood (Pinus sylvestris L.) on cutting forces and roughness during milling. The paper presents the results of research concerning the assessment of machinability of pine wood thermomechanically compacted. The assessment was made on the basis of the cutting forces and surface roughness after the milling process. Selected properties of native and modified wood were examined. Based on the research, it was found that compacted wood is characterized by higher cutting forces during milling. The surface quality after milling was examined and the roughness index Ra values were determined. The research shows that the modified wood is characterized by a lower Ra value both along and across the grain. Statistical analysis showed that the modification had a statistically significant effect on the values of cutting forces and the physical and mechanical properties of the tested wood.

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Geometric Modeling of Cutter/Workpiece Engagements in 3-Axis Milling Using Polyhedral Models

Volume 3: Design and Manufacturing ◽

10.1115/imece2007-41414 ◽

2007 ◽

Author(s):

Eyyup Aras ◽

Derek Yip-Hoi

Keyword(s):

Cutting Forces ◽

Geometric Modeling ◽

Tool Path ◽

Cutting Tool ◽

Milling Process ◽

Mapping Technique ◽

Depth Of Cut ◽

Modeling Methodology ◽

Machining System ◽

Engagement Angle

Modeling the milling process requires cutter/workpiece engagement (CWE) geometry in order to predict cutting forces. The calculation of these engagements is challenging due to the complicated and changing intersection geometry that occurs between the cutter and the in-process workpiece. This geometry defines the instantaneous intersection boundary between the cutting tool and the in-process workpiece at each location along a tool path. This paper presents components of a robust and efficient geometric modeling methodology for finding CWEs generated during 3-axis machining of surfaces using a range of different types of cutting tool geometries. A mapping technique has been developed that transforms a polyhedral model of the removal volume from Euclidean space to a parametric space defined by location along the tool path, engagement angle and the depth-of-cut. As a result, intersection operations are reduced to first order plane-plane intersections. This approach reduces the complexity of the cutter/workpiece intersections and also eliminates robustness problems found in standard polyhedral modeling and improves accuracy over the Z-buffer technique. The CWEs extracted from this method are used as input to a force prediction model that determines the cutting forces experienced during the milling operation. The reported method has been implemented and tested using a combination of commercial applications. This paper highlights ongoing collaborative research into developing a Virtual Machining System.

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