Analytical Modeling and Experimental Validation of Cutting Forces Considering Edge Effects and Size Effects With Round Chamfered Ceramic Tools

2018 ◽  
Vol 140 (8) ◽  
Author(s):  
Kejia Zhuang ◽  
Jian Weng ◽  
Dahu Zhu ◽  
Han Ding
Keyword(s):  
Prediction Model ◽  
Cutting Force ◽  
Edge Effects ◽  
Size Effects ◽  
Cutting Forces ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Reference Plane ◽  
System Transformation ◽  
Cutting Force Prediction

The cutting force is one of the key factors for planning and optimizing the machining operation in material removal processes. An analytical cutting force prediction model that takes into consideration both edge effects and size effects based on the oblique cutting theory is developed and analyzed in this study. A detailed analysis of the cutting geometry is presented based on the coordinate system transformation and uncut chip thickness (UCT), which is evaluated on the rake plane instead of the reference plane. Then, the developed Johnson–Cook constitutive model of the workpiece that takes into consideration the size effects is then applied to the prediction of edge forces coefficients and cutting forces coefficients. The edge forces are predicted using the edge coefficients prediction model with the regularity found in the orthogonal simulations, which reflect the influences of chamfered length and chamfered angle. The developed model is validated using the turning operations of super alloys with round chamfered inserts. Finally, the effects of the cutter edge, cutting parameters, and UCT on the cutting forces are investigated using the developed model. The reasonableness and effectiveness of the proposed model is demonstrated through the comparison of the measured and predicted cutting forces for various chamfer characteristics.

Virtual Five-Axis Flank Milling of Jet Engine Impellers: Part 1 — Mechanics of Five-Axis Flank Milling

2007 ◽  
Author(s):  
W. Ferry ◽  
Y. Altintas
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Friction Angle ◽  
Flank Milling ◽  
Cutting Force Prediction ◽  
Jet Engine ◽  
End Mills ◽  
Five Axis

Jet engine impeller blades are flank-milled with tapered, helical, ball-end mills on five-axis machining centers. The impellers are made from difficult-to-cut titanium or nickel alloys, and the blades must be machined within tight tolerances. As a consequence, deflections of the tool and flexible workpiece can jeopardize the precision of the impellers during milling. This work is the first of a two part paper on cutting force prediction and feed optimization for the five-axis flank milling of an impeller. In Part I, a mathematical model for predicting cutting forces is presented for five-axis machining with tapered, helical, ball-end mills with variable pitch and serrated flutes. The cutter is divided axially into a number of differential elements, each with its own feed coordinate system due to five-axis motion. At each element, the total velocity due to translation and rotation is split into horizontal and vertical feed components, which are used to calculate total chip thickness along the cutting edge. The cutting forces for each element are calculated by transforming friction angle, shear stress and shear angle from an orthogonal cutting database to the oblique cutting plane. The distributed cutting load is digitally summed to obtain the total forces acting on the cutter and blade. The model can be used for general five-axis flank milling processes, and supports a variety of cutting tools. Predicted cutting force measurements are shown to be in reasonable agreement with those collected during a roughing operation on a prototype integrally bladed rotor (IBR).

scholarly journals Cutting Force Modeling and Experimental Study for Ball-End Milling of Free-Form Surfaces

2021 ◽  
Vol 2021 ◽  
pp. 1-18
Author(s):  
Zhaozhao Lei ◽  
Xiaojun Lin ◽  
Gang Wu ◽  
Luzhou Sun
Keyword(s):  
Prediction Model ◽  
Cutting Force ◽  
Chip Thickness ◽  
Free Form ◽  
Force Model ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
Undeformed Chip Thickness ◽  
Free Form Surface ◽  
Free Form Surfaces

In order to improve the machining quality and efficiency and optimize NC machining programming, based on the existing cutting force models for ball-end, a cutting force prediction model of free-form surface for ball-end was established. By analyzing the force of the system during the cutting process, we obtained the expression equation of the instantaneous undeformed chip thickness during the milling process and then determined the rule of the influence of the lead angle and the tilt angle on the instantaneous undeformed chip thickness. It was judged whether the cutter edge microelement is involved in cutting, and the algorithm flow chart is given. After that, the cutting force prediction model of free-form surface for ball-end and pseudocodes for cutting force prediction were given. MATLAB was used to simulate the prediction force model. Finally, through the comparative analysis experiment of the measured cutting force and the simulated cutting force, the experimental results are basically consistent with the theoretical prediction results, which proves that the model established in this paper can accurately predict the change of the cutting force of the ball-end cutter in the process of milling free-form surface, and the error of the cutting force prediction model established in this paper is reduced by 15% compared with the traditional cutting force prediction model.

Experimental Investigations of Cutting Parameters Influence on Cutting Forces and Surface Roughness of Quartz Glass

2013 ◽  
Vol 641-642 ◽  
pp. 367-370
Author(s):  
Gui Qiang Liang ◽  
Fei Fei Zhao
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Diamond Wheel ◽  
Experimental Investigations ◽  
Depth Of Cut ◽  
Feed Force

Abstract In the present study, an attempt has been made to investigate the effect of cutting parameters (cutting speed, feed rate and depth of cut) on cutting forces (feed force, thrust force and cutting force) and surface roughness in milling of Quartz glas using diamond wheel. The cutting process in the up-cut milling of glass is discussed and the cutting force measured. The cutting force gradually increases with the cutter rotation at the beginning of the cut, and oscillates about a constant mean value after a certain undeformed chip thickness. The results show that cutting forces and surface roughness do not vary much with experimental cutting speed in the range of 55–93 m/min. The suggested models of cutting forces and surface roughness and adequately map within the limits of the cutting parameters considered.

Research on Physical Simulation of Virtual CNC Turning

2012 ◽  
Vol 510 ◽  
pp. 50-53
Author(s):  
Chun Lei Li
Keyword(s):  
Steady State ◽  
Prediction Model ◽  
Cutting Force ◽  
Cutting Forces ◽  
Physical Simulation ◽  
Work Piece ◽  
Machining Error ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
Cnc Turning

Sources and measurement of cutting forces are studied to establish the steady-state cutting force prediction model. Modeling of work piece machining error is analyzed, a simplified process coordinate system is established, and the mathematical solving model of machining error within the work piece is given. The cutting force due to work piece bending deformation is studied, a work piece deformation factor error model is established based on steady-state cutting force and the prediction simulation of cutting forces and machining error is achieved.

scholarly journals Cutting Force Prediction Model for Elliptical Vibration Cutting SiCp/Al Based on Three-Phase Friction Theory

2021 ◽  
Vol 11 (22) ◽  
pp. 10737
Author(s):  
Yucheng Li ◽  
Xu Zhang ◽  
Cui Wang
Keyword(s):  
Prediction Model ◽  
Cutting Force ◽  
Cutting Forces ◽  
Volume Fraction ◽  
Cutting Speed ◽  
Contact Length ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
Elliptical Vibration ◽  
Three Phase

The friction behavior in the tool-chip interface is an essential issue in aluminum matrix composite material (AMCM) turning operations. Compared with conventional cutting, the elliptical vibration (EVC) cutting AMCM has attractive advantages, such as low friction, small cutting forces, etc. However, the friction mechanism of the EVC cutting AMCM is still inadequate, especially the model for cutting forces analyzing and predicting, which hinders the application of EVC in the processing of AMCM. In this paper, a cutting force prediction model for EVC cutting SiCp/Al is established, which is based on the three-phase friction (TPF) theory. The friction components are evaluated and predicted at the tool-chip interface (TCI), tool-particle interface (TPI) and tool-matrix (TMI), respectively. In addition, the tool-chip contact length and SiC particle volume fraction were defined strictly and the coefficient of friction was predicted. Based on the Johnson-Cook constitutive model, the experiment was conducted on SiCp/Al. The cutting speed and tool-chip contact length were used as input parameters of the friction model, and the dynamic changes of cutting force and stress distribution were analyzed. The results shown that when cutting speed reaches 574 m/min, the tool-chip contact length decreases to 0.378 mm. When the cutting speed exceeds 658 m/min, the cutting force decreases to a minimum of 214.9 N and remains stable. In addition, compared with conventional cutting, the proposed prediction model can effectively reduce the cutting force.

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.

scholarly journals Adaptive Cutting Force Prediction in Milling Processes

2010 ◽  
Vol 4 (3) ◽  
pp. 221-228 ◽  
Author(s):  
Takashi Matsumura ◽  
◽  
Takahiro Shirakashi ◽  
Eiji Usui
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Flow Model ◽  
Flow Direction ◽  
Orthogonal Cutting ◽  
Cutting Parameters ◽  
Milling Process ◽  
Force Model ◽  
Cutting Force Prediction ◽  
Chip Flow

An adaptive force model is presented to predict the cutting force and the chip flow direction in milling. The chip flow model in the milling process is made by piling up the orthogonal cuttings in the planes containing the cutting velocities and the chip flow velocities. The chip flow direction is determined to minimize the cutting energy. The cutting force is predicted using the determined chip flow model. The force model requires the orthogonal cutting data, which associate the orthogonal cutting models with the cutting parameters. Basically, the required data for simulation can be measured in the orthogonal cutting tests. However, it is difficult to perform the cutting tests with specialized setups in the machine shops. The paper presents the adaptive model to accumulate and update the orthogonal cutting data with referring the measured cutting forces in milling. The orthogonal cutting data are identified to minimize the error between the predicted and the measured cutting forces. Then, the cutting forces can be predicted well in many cutting operations using the identified orthogonal cutting data. The adaptive is effective not only in extending the database but also in improving the quality of the database for the accurate predictions.

SLIP-LINE MODELING OF MACHINING AND DETERMINE THE INFLUENCE OF RAKE ANGLE ON THE CUTTING FORCE

2012 ◽  
Vol 36 (1) ◽  
pp. 23-35 ◽  
Author(s):  
Sabri Ozturk
Keyword(s):  
Cutting Force ◽  
Slip Line ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Uncut Chip Thickness ◽  
Thrust Forces ◽  
Model Approach

In this study, the effects of the rake angle on main cutting force (Fc), and thrust forces (Ft) was investigated. A new slip line model approach for modelling the orthogonal cutting process was proposed. This model was applied at negative rake angles from 0° to –60° and consists of three regions. The main forces were measured with a computer aided quick stop device. Variance Analysis (ANOVA) was utilized to analyze the effects of the cutting parameters on cutting and thrust forces accordingly. Multi-variable regression analysis was also employed to determine the correlations between the factors and the cutting forces. The cutting forces could be calculated by equation parameters which are the rake angle and the uncut chip thickness.

Predictive Modeling of Nonlinear Regenerative Chatter via Measurement, Analysis, and Simulation

1999 ◽  
Author(s):  
J. R. Pratt ◽  
M. A. Davies ◽  
M. D. Kennedy ◽  
T. Kalmár-Nagy
Keyword(s):  
Cutting Force ◽  
Initial Conditions ◽  
Stability Boundary ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Computational Techniques ◽  
Regenerative Chatter ◽  
Stability Lobe ◽  
Measurement Analysis ◽  
On Chip

Abstract A single-degree-of-freedom active cutting fixture is employed to reveal and analyse the hysteretic nature of the lobed stability boundary in a simple machining experiment. Specifically, the seventh stability lobe of a regenerative cutting process is mapped using experimental, analytical, and computational techniques. Then, taking width of cut as a control parameter, the transition from stable cutting to chatter is observed experimentally. The cutting stability is found to possess a substantial hysteresis so that either stable or chattering tool motions can exist at the same nominal cutting parameters, depending on initial conditions. This behavior is predicted by applying nonlinear regenerative chatter theory to an empirical characterization of the cutting force dependence on chip thickness. Time-domain simulations that incorporate both the nonlinear cutting force dependence on chip thickness and the multiple-regenerative effect due to the tool leaving the cut are shown to agree both qualitatively and quantitatively with experiment.

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