Determining the effect of tool posture on cutting force in a turn milling process using an analytical prediction model

2020 ◽  
Vol 150 ◽  
pp. 103511 ◽  
Author(s):  
Koji Utsumi ◽  
Shoki Shichiri ◽  
Hiroyuki Sasahara
Keyword(s):  
Prediction Model ◽  
Cutting Force ◽  
Milling Process ◽  
Analytical Prediction ◽  
Tool Posture ◽  
Turn Milling

Optimization of turn-milling process in roughing and finishing regimes: Trade-off between productivity, cutting force and surface integrity

2021 ◽  
pp. 095440892199851
Author(s):  
Ebrahim Hosseini ◽  
Shafiqur Rehman ◽  
Ashkan Alimoradi
Keyword(s):  
Cutting Force ◽  
Desirability Function ◽  
Milling Process ◽  
Machining Process ◽  
Hybrid Machining ◽  
Trade Off ◽  
Hybrid Machining Process ◽  
Process Factors ◽  
Turn Milling ◽  
Selection Of

Turn-milling is a hybrid machining process which used benefits of interrupted cutting for proceeding of round bars. However, number of controllable parameters in the hybrid process is numerous that makes optimizing the process complicated. In the present study, an optimization work has been proposed to investigate the trade-off between production rate and cutting force in roughing regime as well surface roughness and tensile residual stress in finishing regime. Number of 43 experiments based on response surface methodology was designed and carried out to gather required data for development of quadratic empirical models. Then, the adequacy and importance of process factors were analyzed using analysis of variances. Finally, desirability function was used to optimize the process in rough and finish machining regimes. The obtained results showed that selection of eccentricity and cutter speed at their maximum working range can effectively enhance the quality characteristics in both the roughing and finishing regimes.

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.

Empirical study on ultrasonic assisted turn-milling

2021 ◽  
pp. 095440892110087
Author(s):  
Saeid Amini ◽  
Mohammad Baraheni ◽  
Mohammad Khaki
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Feed Rate ◽  
Rotational Speed ◽  
Milling Process ◽  
Machining Process ◽  
Machining Parameters ◽  
Machining Processes ◽  
Turn Milling

Turn-milling process has been paid attention in order to be used in multi-task machining processes. Moreover, looking for new machining techniques aimed at reducing cutting force is of important. Reducing cutting force in machining processes has the benefits of extending tool life and improving surface quality. One of the new concepts for reducing the cutting force is applying ultrasonic vibration. In this paper, effects of ultrasonic vibration under different machining parameters in turn-milling process of Al-7075 alloy will be investigated. In this order, a special mechanism was designed to apply ultrasonic vibration during machining process. Ultrasonic vibration exertion on the tool reduced cutting force and surface roughness up to 75% and 35%, respectively. Also tool rotational speed increment induced cutting force and surface roughness increment. In addition, tool feed rate and workpiece rotational speed increment caused cutting force and surface roughness increment. Although, feed rate was more influential.

Intelligent Prediction of Tool Wear in Ball-End Milling Process Based on Dimensionless Cutting Force Ratio

2015 ◽  
Vol 799-800 ◽  
pp. 312-318 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Thanathip Jatinandana ◽  
Angsumalin Senjuntichai
Keyword(s):  
Tool Wear ◽  
Prediction Model ◽  
Cutting Force ◽  
End Milling ◽  
Milling Process ◽  
Wear Prediction ◽  
Ball End Milling ◽  
Tool Wear Prediction ◽  
Force Ratio ◽  
End Milling Process

This research proposed an in-process tool wear prediction during the ball-end milling process by utilizing the cutting force ratio. The dimensionless cutting force ratio is proposed to cut off the effects of the work material and the combination of cutting conditions. The in-process tool wear prediction model is developed by employing the exponential function, which consists of the spindle speed, the feed rate, the depth of cut, the tool diameter, and the cutting force ratio. The experimentally obtained results showed that the cutting force ratio can be utilized to predict the tool wear of ball-end milling tool. The new cutting tests have been employed to verify the model and the results run satisfaction. It has been proved that the in-process tool wear prediction model can be used to predict the tool wear regardless of the cutting conditions with the highly acceptable prediction accuracy.

scholarly journals A Prediction Model of Cutting Force about Ball End Milling for Sculptured Surface

2020 ◽  
Vol 2020 ◽  
pp. 1-15
Author(s):  
Wenping Mou ◽  
Shaowei Zhu ◽  
Menghao Zhu ◽  
Lei Han ◽  
Lei Jiang
Keyword(s):  
Prediction Model ◽  
Coordinate System ◽  
Cutting Force ◽  
Sculptured Surface ◽  
Machining Parameters ◽  
End Mill ◽  
Ball End Mill ◽  
Surface Machining ◽  
Sculptured Surface Machining ◽  
Tool Posture

Cutting force prediction is very important to optimize machining parameters and monitor machining state. In order to predict cutting force of sculptured surface machining with ball end mill accurately, tool posture, cutting edge, contact state between cutter, and workpiece are studied. Firstly, an instantaneous motion model of ball end mill for sculptured surface is established. The instantaneous milling coordinate system and instantaneous tool coordinate system are defined to describe the position and orientation of tool, and the transformation matrix between coordinate systems is derived. Secondly, by solving three boundaries around engagement of cutter and workpiece, a cutter-workpiece engagement model related to tool posture, milling parameters, and tool path is established. It has good adaptability to the variable tool axis relative to the machining surface. Finally, an algorithm of thickness about an instantaneous undeformed chip is researched, and a prediction model of cutting force is realized with microelement cutting theory. Also, the model is suitable for sculptured surface machining with arbitrary tool posture and feed direction. The accuracy of the proposed prediction model was verified by a series of experiments.

scholarly journals Research on Cutting Force of Turn-Milling Based on Thin-Walled Blade

2016 ◽  
Vol 2016 ◽  
pp. 1-11 ◽  
Author(s):  
Lida Zhu ◽  
Baoguang Liu ◽  
Xiaobang Wang ◽  
Zhiwei Xu
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Metal Removal ◽  
Cutting Parameters ◽  
Milling Process ◽  
Cutting Condition ◽  
Deformation Properties ◽  
Mechanism Research ◽  
Thin Walled ◽  
Turn Milling

Turn-milling is regarded as the milling of a curved surface while rotating the workpiece around its center point, which combines effectively the advantages of both turning and milling, wherein it allows for good metal removal with the difficult-to-cut thin-walled workpieces in aviation. The objective of the present work is to study cutting force by turn-milling in cutting condition. Aiming at the deformation properties of thin-walled blade, the predicted models of rigid cutting force and flexible cutting force with ball cutter are provided, respectively, in turn-milling process. The deformation values of blade and cutter are calculated, respectively, based on the engaged trajectory by using the iterative algorithm. The rigid and flexible cutting forces are compared and the influence degrees of cutting parameters on cutting forces are analyzed. These conclusions provide theoretical foundation and reference for turn-milling mechanism research.

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