On-line cutting force coefficients identification for bull-end milling process with vibration

In order to realize the intelligent machines, the practical model is proposed to predict the in-process surface roughness during the ball-end milling process by utilizing the cutting force ratio. The ratio of cutting force is proposed to be generalized and non-scaled to estimate the surface roughness regardless of the cutting conditions. The proposed in-process surface roughness model is developed based on the experimentally obtained data by employing the exponential function with five factors of the spindle speed, the feed rate, the tool diameter, the depth of cut, and the cutting force ratio. The prediction accuracy and the prediction interval of the in-process surface roughness model at 95% confident level are calculated and proposed to predict the distribution of individually predicted points in which the in-process predicted surface roughness will fall. All those parameters have their own characteristics to the arithmetic surface roughness and the surface roughness. It is proved by the cutting tests that the proposed and developed in-process surface roughness model can be used to predict the in-process surface roughness by utilizing the cutting force ratio with the highly acceptable prediction accuracy.

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A Mechanistic Model of Cutting Forces in Micro-End-Milling With Cutting-Condition-Independent Cutting Force Coefficients

Journal of Manufacturing Science and Engineering ◽

10.1115/1.2917300 ◽

2008 ◽

Vol 130 (3) ◽

Cited By ~ 30

Author(s):

Han Ul Lee ◽

Dong-Woo Cho ◽

Kornel F. Ehmann

Keyword(s):

Cutting Force ◽

Cutting Forces ◽

End Milling ◽

Cutting Conditions ◽

Thickness Effect ◽

Force Model ◽

Cutting Force Coefficients ◽

Force Coefficients ◽

Micro End Milling ◽

Cutting Mechanisms

Complex three-dimensional miniature components are needed in a wide range of industrial applications from aerospace to biomedicine. Such products can be effectively produced by micro-end-milling processes that are capable of accurately producing high aspect ratio features and parts. This paper presents a mechanistic cutting force model for the precise prediction of the cutting forces in micro-end-milling under various cutting conditions. In order to account for the actual physical phenomena at the edge of the tool, the components of the cutting force vector are determined based on the newly introduced concept of the partial effective rake angle. The proposed model also uses instantaneous cutting force coefficients that are independent of the end-milling cutting conditions. These cutting force coefficients, determined from measured cutting forces, reflect the influence of the majority of cutting mechanisms involved in micro-end-milling including the minimum chip-thickness effect. The comparison of the predicted and measured cutting forces has shown that the proposed method provides very accurate results.

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Prediction of chatter considering the effect of axial cutting depth on cutting force coefficients in end milling

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-018-1745-z ◽

2018 ◽

Vol 96 (9-12) ◽

pp. 3345-3354 ◽

Cited By ~ 3

Author(s):

Guang Yu ◽

Liping Wang ◽

Jun Wu

Keyword(s):

Cutting Force ◽

End Milling ◽

Cutting Depth ◽

Cutting Force Coefficients ◽

Force Coefficients

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

Proceedings of the Institution of Mechanical Engineers Part C Journal of Mechanical Engineering Science ◽

10.1177/0954406218781966 ◽

2018 ◽

Vol 233 (7) ◽

pp. 2248-2261 ◽

Cited By ~ 1

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.

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Optimization of Process Parameters for Cutting Force for Aluminium 7010 in CNC End Milling Process

International Journal of Vehicle Structures and Systems ◽

10.4273/ijvss.10.6.04 ◽

2018 ◽

Vol 10 (6) ◽

Author(s):

M. Kishanth ◽

P. Rajkamal ◽

D. Karthikeyan ◽

K. Anand

Keyword(s):

Surface Roughness ◽

Cutting Force ◽

Process Parameters ◽

End Milling ◽

Milling Process ◽

Machining Process ◽

Depth Of Cut ◽

Optimization Of Process Parameters ◽

Cnc End Milling ◽

End Milling Process

In this paper CNC end milling process have been optimized in cutting force and surface roughness based on the three process parameters (i.e.) speed, feed rate and depth of cut. Since the end milling process is used for abrading the wear caused is very high, in order to reduce the wear caused by high cutting force and to decrease the surface roughness, the optimization is much needed for this process. Especially for materials like aluminium 7010, this kind of study is important for further improvement in machining process and also it will improve the stability of the machine.

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