Cutting force model considering tool edge geometry for micro end milling process

2008 ◽  
Vol 22 (2) ◽  
pp. 293-299 ◽  
Author(s):  
Ik Soo Kang ◽  
Jeong Suk Kim ◽  
Yong Wie Seo
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Milling Process ◽  
Force Model ◽  
Cutting Force Model ◽  
Edge Geometry ◽  
Tool Edge ◽  
Micro End Milling ◽  
End Milling Process

Dynamic cutting force prediction for micro end milling considering tool vibrations and run-out

2018 ◽  
Vol 233 (7) ◽  
pp. 2248-2261 ◽  
Author(s):  
Xuewei Zhang ◽  
Tianbiao Yu ◽  
Wanshan Wang
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Chip Thickness ◽  
Milling Process ◽  
Force Model ◽  
Dynamic Cutting Force ◽  
Micro End Milling ◽  
Tool Vibrations ◽  
End Milling Process

An accurate prediction of cutting forces in the micro end milling, which is affected by many factors, is the basis for increasing the machining productivity and selecting optimal cutting parameters. This paper develops a dynamic cutting force model in the micro end milling taking into account tool vibrations and run-out. The influence of tool run-out is integrated with the trochoidal trajectory of tooth and the size effect of cutting edge radius into the static undeformed chip thickness. Meanwhile, the real-time tool vibrations are obtained from differential motion equations with the measured modal parameters, in which the process damping effect is superposed as feedback on the undeformed chip thickness. The proposed dynamic cutting force model has been experimentally validated in the micro end milling process of the Al6061 workpiece. The tool run-out parameters and cutting forces coefficients can be identified on the basis of the measured cutting forces. Compared with the traditional model without tool vibrations and run-out, the predicted and measured cutting forces in the micro end milling process show closer agreement when considering tool vibrations and run-out.

A Mechanistic Cutting Force Model for 3D Ball-end Milling

2000 ◽  
Vol 123 (1) ◽  
pp. 23-29 ◽  
Author(s):  
Hsi-Yung Feng ◽  
Ning Su
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Chip Thickness ◽  
Milling Process ◽  
Force Model ◽  
Cutting Force Model ◽  
Ball End Milling ◽  
End Milling Process ◽  
Force Relationship

This paper presents an improved mechanistic cutting force model for the ball-end milling process. The objective is to accurately model the cutting forces for nonhorizontal and cross-feed cutter movements in 3D finishing ball-end milling. Main features of the model include: (1) a robust cut geometry identification method to establish the complicated engaged area on the cutter; (2) a generalized algorithm to determine the undeformed chip thickness for each engaged cutting edge element; and (3) a comprehensive empirical chip-force relationship to characterize nonhorizontal cutting mechanics. Experimental results have shown that the present model gives excellent predictions of cutting forces in 3D ball-end milling.

An improved dynamic cutting force model for end-milling process

2004 ◽  
Vol 148 (3) ◽  
pp. 317-327 ◽  
Author(s):  
Shih-Ming Wang ◽  
Chu-Hsiang Chiou ◽  
Yuan-Ming Cheng
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Milling Process ◽  
Force Model ◽  
Cutting Force Model ◽  
Dynamic Cutting Force ◽  
End Milling Process

Cutting Force Prediction for Generalized Cornering Milling Process

2011 ◽  
Vol 188 ◽  
pp. 404-409 ◽  
Author(s):  
Xue Yan ◽  
Hua Tao ◽  
D.H. Zhang ◽  
B.H. Wu
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Milling Process ◽  
Force Model ◽  
Cutting Force Model ◽  
Cutting Force Prediction ◽  
Geometric Relationship ◽  
The Mathematical Model ◽  
Good Agreement

A developed method to predict the cutting forces in end milling of generalized corners is proposed in this paper. The cornering milling process is divided into a series of cutting segments with different cutting states. The mathematical model of the geometric relationship between cutter and the corner profile is established for each segment. Cutting forces is predicted by introducing the classical cutting force model. The computational results of cutting forces are in good agreement with experimental data.

Numerical Simulation and Experimental Investigation of Tool Edge Radius Effect on Micro-Cutter Wear in Micro-End-Milling Process

2010 ◽  
Vol 97-101 ◽  
pp. 2542-2545 ◽  
Author(s):  
Kai Yang ◽  
Qing Shun Bai ◽  
Ying Chun Liang
Keyword(s):  
Aluminum Alloy ◽  
Effective Stress ◽  
End Milling ◽  
Milling Process ◽  
Experimental Results ◽  
Tool Edge ◽  
Cutter Wear ◽  
Micro End Milling ◽  
Aluminum Alloy 2024 ◽  
End Milling Process

The micro-end-milling process of aluminum alloy Al2024-T6 has been investigated by numerical simulations and experimental approach. The effects of different tool edge radii on the micro-cutter wear were investigated. A three-dimensional finite element model is adopted to determine the effects of tool edge radii on the effective stress and micro-cutter wear during the micro-end-milling process. It is observed that the the tool nose wears out much more quickly due to the high maximal effective stress occurring in this zone. The experimental verification of the simulation model is carried out on a micro-end-milling process of aluminum alloy 2024-T6. The experimental results of the micro-cutter morphologies are in a good agreement with the simulation results. The experimental results show that the model is suitable for studying the mechanism of micro-cutter wear.

An Experimental and Modeling Study on Meso/Micro End Milling Process

2006 ◽  
Author(s):  
Atul Dhanorker ◽  
Tugˇrul O¨zel
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
End Milling ◽  
Milling Process ◽  
Element Modeling ◽  
Temperature Distributions ◽  
Tool Edge ◽  
Micro End Milling ◽  
Al 2024 ◽  
End Milling Process

In this paper, mechanistic and finite element modeling of meso/micro end milling process with predictions of forces, stresses and temperature distributions in the presence of tool edge ploughing are presented. The finite element modeling of micro end milling without considering tool-workpiece dynamics interaction is introduced to study the effects of cutting conditions on the workpiece deformations in meso/micro end milling. Model is tested and validated for temperature and force predictions in meso/micro end milling of AL 2024-T6 aluminum.

Hierarchical Optimal Force–Position Control of Complex Manufacturing Processes

2012 ◽  
Author(s):  
Hesam Zomorodi Moghadam ◽  
Robert G. Landers ◽  
S. N. Balakrishnan
Keyword(s):  
Cutting Force ◽  
Position Control ◽  
End Milling ◽  
Milling Process ◽  
Optimal Controller ◽  
Depth Of Cut ◽  
Force Model ◽  
Bottom Level ◽  
Reference Velocity ◽  
Micro End Milling

A hierarchical optimal controller is developed to regulate the cutting force and tool position, simultaneously, in a micro end milling process. The process is divided into two levels of decision making. The bottom level includes the measurable states, which in this work comprise the servomechanism positions. The top level includes the higher order objectives which can be derived from the bottom level objectives by an aggregation relationship. In this work the top level objective is concerned with cutting force regulation. The aggregation relations are linearized to fit into a linear optimal control problem to reduce the computational efforts. Reference velocity is calculated based on the force model, using the desired depth-of-cut and spindle speed. The proposed method is compared to a normal optimal controller without considering the top level objectives. Comparison between the two methods reveals the advantages of considering the top level objectives.

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