Comprehensive Dynamic Cutting Force Model and Its Application to Wave-Removing Processes

1988 ◽  
Vol 110 (2) ◽  
pp. 153-161 ◽  
Author(s):  
D. W. Wu
Keyword(s):  
Cutting Force ◽  
Machining Process ◽  
Plastic Deformation Zone ◽  
Force Model ◽  
Cutting Force Model ◽  
Dynamic Cutting Force ◽  
Theoretical Predictions ◽  
Force Variation ◽  
The Mean ◽  
Good Agreement

A new concept is taken to develop a comprehensive cutting force model for analyzing the dynamic behavior of the machining process. The model is derived based on the principles of the cutting mechanics, and takes into account the fluctuation of the mean factional coefficient on the tool-chip interface as well as the variations of the normal hydrostatic pressure distribution and the shear flow stress along the primary plastic deformation zone. The model has been tested through computer simulation for orthogonal wave-removing processes by reference to an existing experimental evidence. The result indicates a generally good agreement with the theoretical predictions except that the amplitude of the force variation in the feeding direction appears to be underestimated. An explanation is also given.

scholarly journals Experimental investigations of chatter and critical cutting conditions in turning

2021 ◽  
Author(s):  
Vipul Shah
Keyword(s):  
Cutting Force ◽  
Orthogonal Cutting ◽  
Experimental Results ◽  
Experimental Investigations ◽  
Force Model ◽  
Cutting Force Model ◽  
The Arts ◽  
Dynamic Cutting Force ◽  
Theoretical Predictions ◽  
Series Of Experiments

Vibration can cause problems when it occurs during machining, especially if it cannot be damped and continuous to increase, a phenomenon known as chatter. This thesis project focuses on reviewing the state-of-the-arts work in chatter research, identifying a reliable mechanistic dynamic cutting force model for orthogonal cutting operations when machining slender shafts, carrying out a series of experiments on uniform and stepped workpiece[s], and validating the theoretical predictions of chatter onset conditions against experimental results.

scholarly journals Experimental investigations of chatter and critical cutting conditions in turning

2021 ◽  
Author(s):  
Vipul Shah
Keyword(s):  
Cutting Force ◽  
Orthogonal Cutting ◽  
Experimental Results ◽  
Experimental Investigations ◽  
Force Model ◽  
Cutting Force Model ◽  
The Arts ◽  
Dynamic Cutting Force ◽  
Theoretical Predictions ◽  
Series Of Experiments

Vibration can cause problems when it occurs during machining, especially if it cannot be damped and continuous to increase, a phenomenon known as chatter. This thesis project focuses on reviewing the state-of-the-arts work in chatter research, identifying a reliable mechanistic dynamic cutting force model for orthogonal cutting operations when machining slender shafts, carrying out a series of experiments on uniform and stepped workpiece[s], and validating the theoretical predictions of chatter onset conditions against experimental results.

Improved dynamic cutting force modelling in micro milling of metal matrix composites part II: Experimental validation and prediction

2019 ◽  
Vol 234 (8) ◽  
pp. 1500-1515
Author(s):  
Zhichao Niu ◽  
Kai Cheng
Keyword(s):  
Cutting Force ◽  
Metal Matrix Composites ◽  
Cutting Forces ◽  
Metal Matrix ◽  
Micro Milling ◽  
Force Model ◽  
Matrix Composites ◽  
Cutting Force Model ◽  
Side Milling ◽  
Dynamic Cutting Force

The effects of cutting dynamics and the particles' size and density cannot be ignored in micro milling of metal matrix composites. This article presents the improved dynamic cutting force modelling for micro milling of metal matrix composites based on the previous analytical model. This comprehensive improved cutting force model, taking the influence of the tool run-out, actual chip thickness and resultant tool tip trajectory into account, is evaluated and validated through well-designed machining trials. A series of side milling experiments using straight flutes polycrystalline diamond end mills are carried out on the metal matrix composite workpiece under various cutting conditions. Subsequently, the measured cutting forces are compensated by a Kalman filter to achieve the accurate cutting forces. These are further compared with the predicted cutting forces to validate the proposed dynamic cutting force model. The experimental results indicate that the predicted and measured cutting forces in micro milling of metal matrix composites are in good agreement.

Research on Feedrate Optimization Based on Cutting Force Model with Double Effect for the Ball-End Milling

2011 ◽  
Vol 291-294 ◽  
pp. 2965-2969
Author(s):  
Yu Jun Cai ◽  
Hua Shen ◽  
Tie Li Qi
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Double Effect ◽  
Machining Process ◽  
Force Model ◽  
Optimization Strategy ◽  
Cutting Force Model ◽  
Ball End Mill ◽  
Ball End Milling ◽  
Feedrate Optimization

A new cutting force model of ball-end mill with double effect is developed through analysing the machining process by using differential geometry. The cutting force model is needed to be revised for the component force in Z direction because of the offset to the actual results. The cutting force and the ball-end milling force coefficients can be given with numerical method. A feedrate optimization strategy is also proposed based on the developed cutting force model and tested effectively.

An Implementation of Analytical Boundary Simulation on Feedrate Scheduling during Semi-Finish Milling

2016 ◽  
Vol 851 ◽  
pp. 211-215
Author(s):  
Hendriko Hendriko
Keyword(s):  
Cutting Forces ◽  
Machining Process ◽  
Depth Of Cut ◽  
Force Model ◽  
Cutting Force Model ◽  
Feedrate Scheduling ◽  
Helical Angle ◽  
Result Show ◽  
Five Axis ◽  
Good Agreement

In five-axis milling, determining the continuously changing Cutter Workpiece Engagement (CWE) remains a challenge. All the feedrate calculation method that have been reported need a precise information about Cutter Workpiece Engagement. In this paper, the cut geometry was calculated using an analytical method called Analytical Boundary Simulation (ABS). This method was reported accurate and less expensive in term of calculation time. The cut geometry data was then used to calculate the instantaneous cutting forces. A new mechanistic force model was developed by taken into account the variation of axial depth of cut, the feedrate, the tool orientation, and the helical angle. Analytical boundary simulation and mechanisitic cutting force model were then used to optimize a semi finish machining process using feedrate scheduling. The applicability of the proposed method was verified experimentally and the result show that the calculated cutting forces of feedrate scheduling have a good agreement with those obtained from the experimental work.

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.

Calibration of a Milling Force Model Using Feed and Spindle Power Sensors

2008 ◽  
Author(s):  
Bryan Javorek ◽  
Barry K. Fussell ◽  
Robert B. Jerard
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Machining Process ◽  
Force Model ◽  
Cutting Force Model ◽  
Drive Power ◽  
Average Force ◽  
Force Monitoring ◽  
Milling Force Model

Changes in cutting forces during a milling operation can be associated with tool wear and breakage. Accurate monitoring of these cutting forces is an important step towards the automation of the machining process. However, direct force sensors, such as dynamometers, are not practical for industry application due to high costs, unwanted compliance, and workspace limitations. This paper describes a method in which power sensors on the feed and spindle motors are used to generate coefficients for a cutting force model. The resulting model accurately predicts the X and Y cutting forces observed in several simple end-milling tests, and should be capable of estimating both the peak and average force for a given cut geometry. In this work, a dynamometer is used to calibrate the feed drive power sensor and to measure experimental cutting forces for verification of the cutting force model. Measurement of the average x-axis cutting forces is currently presented as an off-line procedure performed on a sacrificial block of material. The potential development of a continuous, real-time force monitoring system is discussed.

Establishment and verification of a dynamic cutting force model for metal bandsawing

2016 ◽  
Vol 90 (9-12) ◽  
pp. 2703-2712
Author(s):  
Jing Ni ◽  
Lu Li ◽  
M. S. H. Al-Furjan ◽  
Jing Xu ◽  
Xiao Yang
Keyword(s):  
Cutting Force ◽  
Force Model ◽  
Cutting Force Model ◽  
Dynamic Cutting Force
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