The Role of Flank Face Interference in Improving the Accuracy of Dynamic Force Predictions in Peripheral Milling

1999 ◽  
Vol 121 (4) ◽  
pp. 593-599 ◽  
Author(s):  
S. Ranganath ◽  
K. Narayanan ◽  
J. W. Sutherland
Keyword(s):  
Cutting Forces ◽  
Milling Process ◽  
Total Force ◽  
Dynamic Force ◽  
Peripheral Milling ◽  
Flank Face ◽  
Simulation Results ◽  
Chip Removal ◽  
Interference Mechanism

An enhanced model for the dynamic behavior of the peripheral milling process is described. The model predicts the cutting forces and cutter deflections by including the effects of the flank face interference mechanism in addition to the chip removal effects. The interference mechanism is accounted for by considering the flank interference forces to be proportional to the interference volume. The volume of interference is estimated numerically. The total force acting on the tool is a combination of the forces due to the cutting action and forces due to the interference. Experiments performed on 6061-T6 Aluminum validate the simulation results.

Dynamic Force Identification in Peripheral Milling Based on CGLS Using Filtered Acceleration Signals and Averaged Transfer Functions

2019 ◽  
Vol 141 (6) ◽  
Author(s):  
Chenxi Wang ◽  
Xingwu Zhang ◽  
Baijie Qiao ◽  
Hongrui Cao ◽  
Xuefeng Chen
Keyword(s):  
Time Domain ◽  
Transfer Functions ◽  
Milling Process ◽  
Dynamic Force ◽  
Band Pass Filter ◽  
Peripheral Milling ◽  
Milling Force ◽  
Force Identification ◽  
Milling Forces ◽  
Acceleration Signals

Dynamic milling forces have been widely used to monitor the condition of the milling process. However, it is very difficult to measure milling forces directly in operation, particularly in the industrial scene. In this paper, a dynamic force identification method in time domain, conjugate gradient least square (CGLS), is employed for reconstructing the time history of milling forces using acceleration signals in the peripheral milling process. CGLS is adopted for force identification because of its high accuracy and efficiency, which handles the ill-conditioned matrix well. In the milling process, the tool with high-speed rotation has different transfer functions between tool nose and accelerometers at different angular positions. Based on this fact, the averaged transfer functions are employed to reduce the error amplification of regularization processing for milling force identification. Moreover, in order to eliminate the effect of idling and high-frequency components on identification accuracy, the Butterworth band-pass filter is adopted for acceleration signals preprocessing. Finally, the proposed method is validated by milling tests under different cutting parameters. Experimental results demonstrate that the identified and measured milling forces are in good agreement on the whole time domain, which verifies the effectiveness and generalization of the indirect method for milling force measuring. In addition, the Tikhonov regularization method is also implemented for comparison, which shows that CGLS has higher accuracy and efficiency.

Identification of Cutter Axis Tilt in End Milling

1997 ◽  
Vol 119 (2) ◽  
pp. 178-185 ◽  
Author(s):  
Li Zheng ◽  
S. Y. Liang
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Milling Process ◽  
Mathematical Representation ◽  
Thickness Variation ◽  
Dynamic Force ◽  
Force Components

The scope of the paper is to discuss the identification of cutter axis tilt in end milling process via cutting force analysis. Cutter axis tilt redistributes the chip load among flutes thereby generating minor frequency components of cutting forces. These minor components can be utilized to infer the tilt geometry during the cutting action. This study involved the mathematical representation of chip thickness variation due to tilt, the modeling of local forces in relation to instantaneous chip thickness, the formulation of total cutting forces through convolution integration in the angle domain, the derivation of dynamic force components in the frequency domain, and the solution for tilt geometry from the dynamic cutting forces. Results show that the tilt magnitude and orientation can be estimated given the dynamic cutting force components along with the tool/work geometry, cutting parameters, and machining configuration. Numerical simulation results confirmed the validity of the angle domain convolution approach, and the end milling experimental data agreed with the analytical model.

Numerical Model for Prediction of Cutting Force in Peripheral Milling Process Including Thrust and Tangential Damping

2011 ◽  
Vol 223 ◽  
pp. 122-132
Author(s):  
Kamel Mehdi ◽  
Ali Zghal
Keyword(s):  
Numerical Model ◽  
Cutting Force ◽  
Helix Angle ◽  
Milling Process ◽  
Cutting Process ◽  
Force Model ◽  
Total Force ◽  
Peripheral Milling ◽  
Process Damping ◽  
Tool Diameter

A numerical model for prediction of cutting force components in peripheral milling process, including the cutting process damping, is proposed. The cutting process damping creates two components (thrust and tangential) of a dynamic cutting force. The total force model is obtained through numerical integration of the local forces. The effects of tool parameters (diameter, helix angle, number of teeth) on process damping and cutting force distributions are discussed. It is shown that the average value of the process damping and the amplitude of the cutting force increase with increasing the tool diameter. On the other hand, when the tool helix angle increases the process damping increases and the cutting force decreases. The number of tool teeth’s has not an influence on the variation of the damping process and cutting force but an influence on the number of cycles of the periodic cutting process.

Modelling and Simulation of Cutting Forces in Micromachining

2010 ◽  
Vol 443 ◽  
pp. 652-656
Author(s):  
Shah Md. Mahfuzur Rahman ◽  
Jong Leng Liow
Keyword(s):  
Cutting Forces ◽  
Force Model ◽  
Micro Machining ◽  
Machining Processes ◽  
Tool Failure ◽  
Planning Optimization ◽  
Optimization And Control ◽  
Flank Face ◽  
Simulation Results ◽  
And Control

The analysis of cutting forces plays an important role in the design of machine tool systems as well as in the planning, optimization, and control of micro machining processes. Several parameters influence the cutting forces of which the friction is important in causing premature tool failure. This paper presents a force model that includes the friction force for sliding due to the contact between the tool and workpiece at the flank face. Simulation results were compared with the experimental results of Bao and Tansel [1] showing that the model can satisfactorily represent the cutting forces in two dimensional cutting.

scholarly journals Towards Efficient Milling of Multi-Cavity Aeronautical Structural Parts Considering ACO-Based Optimal Tool Feed Position and Path

Micromachines ◽  
2021 ◽  
Vol 12 (1) ◽  
pp. 88
Author(s):  
Yupeng Xin ◽  
Yuanheng Li ◽  
Wenhui Li ◽  
Gangfeng Wang
Keyword(s):  
High Speed ◽  
Tool Path ◽  
Milling Process ◽  
Ant Colony ◽  
Machining Accuracy ◽  
Ant Colony Optimization Algorithm ◽  
Peripheral Milling ◽  
Structural Part ◽  
Milling Method ◽  
Structural Parts

Cavities are typical features in aeronautical structural parts and molds. For high-speed milling of multi-cavity parts, a reasonable processing sequence planning can significantly affect the machining accuracy and efficiency. This paper proposes an improved continuous peripheral milling method for multi-cavity based on ant colony optimization algorithm (ACO). Firstly, by analyzing the mathematical model of cavity corner milling process, the geometric center of the corner is selected as the initial tool feed position. Subsequently, the tool path is globally optimized through ant colony dissemination and pheromone perception for path solution of multi-cavity milling. With the advantages of ant colony parallel search and pheromone positive feedback, the searching efficiency of the global shortest processing path is effectively improved. Finally, the milling programming of an aeronautical structural part is taken as a sample to verify the effectiveness of the proposed methodology. Compared with zigzag milling and genetic algorithm (GA)-based peripheral milling modes in the computer aided manufacturing (CAM) software, the results show that the ACO-based methodology can shorten the milling time of a sample part by more than 13%.

Development of Three-Dimensional Parametric Modeling for Milling Process Simulation

2010 ◽  
Vol 139-141 ◽  
pp. 1178-1183
Author(s):  
Jing Sheng ◽  
Guang Guo Zhang ◽  
Hong Hua Zhang
Keyword(s):  
3D Modeling ◽  
Process Simulation ◽  
Three Dimensional ◽  
Milling Process ◽  
Parametric Modeling ◽  
Machining Simulation ◽  
Metal Machining ◽  
Simulation Results ◽  
Key Techniques ◽  
Access Data

Metal machining simulation using finite element method (FEM) is extraordinarily complex. It is essential to develop a system so as to construct simulation model and obtain valuable results conveniently and rapidly. This study developed a parametric modeling based on MSC.Marc software, which included the key techniques of three-dimensional (3D) modeling and the parametric modeling course of metal milling process. In addition, an explanation facility based on the procedure file, which could be run automatically, was performed according to a modeling procedure. The interface of the system designed using Builder, could access data, which included the geometric angles and the dimensions of a tool and a workpiece, the relative position between them, their properties and cutting conditions, etc.. Calling the procedure file, the system approached the parametric modeling. An example was given, which simulation results indicated that it is an effective methodology to develop 3D parametric modeling.

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