Analytical cutting force modelling of micro-slot grinding considering tool-workpiece interactions on both primary and secondary tool surfaces

2021 ◽  
pp. 1-43
Author(s):  
Ashwani Pratap ◽  
Karali Patra
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Surface Interactions ◽  
Surface Interaction ◽  
Edge Density ◽  
Force Model ◽  
Height Distribution ◽  
Force Modeling ◽  
Tool Surface

Abstract This work presents an analytical cutting force modeling for micro-slot grinding. Contribution of the work lies in the consideration of both primary and secondary tool surface interactions with the work surface as compared to the previous works where only primary tool surface interaction was considered during cutting force modeling. Tool secondary surface interaction with workpiece is divided into two parts: cutting/ ploughing by abrasive grits present in exterior margin of the secondary tool surface and sliding/adhesion by abrasive grits in the inner margins of the secondary tool surface. Orthogonal cutting force model and indentation based fracture model is considered for cutting by both the abrasives of primary tool surface and the abrasives of exterior margin on the secondary surface. Asperity level sliding and adhesion model is adopted to solve the interaction between the workpiece and the interior margin abrasives of secondary tool surface. Experimental measurement of polycrystalline diamond tool surface topography is carried out and surface data is processed with image processing tools to determine the tool surface statistics viz., cutting edge density, grit height distribution and abrasive grit geometrical measures. Micro-slot grinding experiments are carried out on BK7 glass at varying feed rate and axial depths of cut to validate the simulated cutting forces. Simulated cutting forces considering both primary and secondary tool surface interactions are found to be much closer to the experimental cutting forces as compared to the simulated cutting forces considering only primary tool surface interaction.

Modeling the Chip-Work Contact Force for Chip Breaking in Orthogonal Machining With a Flat-Faced Tool

1998 ◽  
Vol 120 (1) ◽  
pp. 49-56 ◽  
Author(s):  
B. K. Ganapathy ◽  
I. S. Jawahir
Keyword(s):  
Cutting Force ◽  
Contact Force ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Force Model ◽  
Two Dimensional ◽  
Cutting Force Model ◽  
Chip Breaking ◽  
Orthogonal Machining

The present tendency towards increased automation of metal cutting operations has resulted in a need to develop a model for the chip breaking process. Conventional cutting force models do not have any provision for the study of chip breaking since they assume a continuous mode of chip formation, where the contact action of the free-end of the chip is ignored in all analyses. The new cutting force model proposed in this work incorporates the contact force developed due to the free-end of the chip touching the workpiece, and is applicable to the study of two-dimensional chip breaking in orthogonal machining. Orthogonal cutting tests were performed to obtain two-dimensional chip breaking. The experimentally measured cutting forces show a good correlation with the estimated cutting forces using the model. Results show that the forces acting on the chip vary within a chip breaking cycle and help identify the chip breaking event.

Analysis of Cutting Forces in Precision Turning Based on Oblique Cutting Model

2010 ◽  
Vol 97-101 ◽  
pp. 1961-1964 ◽  
Author(s):  
Wei Guo Wu ◽  
Gui Cheng Wang ◽  
Chun Gen Shen
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Differential Method ◽  
Force Model ◽  
Cutting Force Model ◽  
Linear Change ◽  
Oblique Cutting ◽  
Precision Turning ◽  
Cutting Model

In this work, the prediction and analysis of cutting forces in precision turning operations is presented. The model of cutting forces is based on the oblique cutting force model which was rebuilt by two coordinate conversions from the orthogonal cutting model. Then the cutting field in precision turning was divided into two fields which are characterized as curve change and linear change on cutter edge and they were modeled respectively. Cutting field of cutter nose was modeled by differential method and its cutting force distribution is predicted by the proposed method. The predicted results for the cutting forces are in agreement with the experimental results under a variety of operation variables, including changes in the depths of cut and in the feedrate.

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.

scholarly journals Cutting Force in Milling of Additive Manufacturing AISI 420 Stainless Steel

2021 ◽  
Author(s):  
Shoichi Tamura ◽  
Takashi Matsumura
Keyword(s):  
Stainless Steel ◽  
Additive Manufacturing ◽  
Cutting Force ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Force Model ◽  
Additive Process ◽  
Aisi 420 ◽  
Chip Flow ◽  
Cutting Model

In manufacturing, hybrid systems of metal additive manufacturing and cutting in the same platform have been attractive in terms of low volume production of customized parts, complex shape, and fine surface finish. Milling is conducted to finish rough surface fabricated in additive process. The fundamental machinability of the additive workpiece should be studied because the material properties are different from metals produced in the conventional process. The paper discusses the cutting forces in milling of AISI 420 stainless steel fabricated in additive process. The cutting tests were conducted to measure the cutting forces and the chip morphologies for tool geometries. The cutting forces were also analyzed in an energy-based force model. In the analysis model, three-dimensional chip flow is interpreted as a piling up of orthogonal cuttings in the planes containing the cutting velocities and the chip flow velocities, where the cutting model is made by the orthogonal cutting data acquired in cutting tests. The chip flow direction is determined to minimize the cutting energy. The cutting forces, then, were predicted in the determined chip flow model. The cutting force model was validated in comparison of simulated forces with the actual ones.

ANISOTROPIC CUTTING FORCE CHARACTERISTICS IN MILLING OF MARAGING STEEL PROCESSED THROUGH SELECTIVE LASER MELTING

2021 ◽  
pp. 1-16
Author(s):  
Shoichi Tamura ◽  
Takashi Matsumura ◽  
Atsushi Ezura ◽  
Kazuo Mori
Keyword(s):  
Additive Manufacturing ◽  
Cutting Force ◽  
Maraging Steel ◽  
Selective Laser Melting ◽  
Cutting Forces ◽  
Manufacturing Process ◽  
Laser Scanning ◽  
Force Model ◽  
Laser Melting ◽  
Scanning Direction

Abstract Additive manufacturing process of maraging steel has been studied for high value parts in aerospace and automotive industries. The hybrid additive / subtractive manufacturing is effective to achieve tight tolerances and surface finishes. The additive process induces anisotropic mechanical properties of maraging steel, which depends on the laser scanning direction. Because anisotropy in the workpiece material has an influence on the cutting process, the surface finish and the dimension accuracy change according to the direction of the cutter feed with respect to the laser scanning direction. Therefore, the cutting parameters should be determined to control the cutting force considering material anisotropy. The paper discusses the cutting force in milling of maraging steel stacked with selective laser melting, as an additive manufacturing process. Anisotropic effect on the cutting forces is proved with the changing rate of the cutting force in milling of the workpieces stacked by repeating laser scanning at 0/90 degrees and 45/-45 degrees. The cutting forces, then, are analyzed in the chip flow models with piling up of orthogonal cuttings. The force model associates anisotropy with the shear stress on the shear plane. The changes in the cutting forces with the feed direction are discussed in the cutting tests and analysis.

Statistical Cutting Force Model for Orthogonal Cutting of Polytetrafluoroethylene (PTFE) Composites

2013 ◽  
Author(s):  
Felicia Stan ◽  
Daniel Vlad ◽  
Catalin Fetecau
Keyword(s):  
Friction Coefficient ◽  
Cutting Force ◽  
Feed Rate ◽  
Normal Force ◽  
Polynomial Regression ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Tool Geometry ◽  
Force Model

This paper presents an experimental investigation of the cutting forces response during the orthogonal cutting of polytetrafluoroethylene (PTFE) and PTFE-based composites using the Taguchi method. Cutting experiments were conducted using the L27 orthogonal array and the effects of the cutting parameters (feed rate, cutting speed and rake angle) on the cutting force were analyzed using the S/N ratio response and the analysis of variance (ANOVA). Statistical models that correlate the cutting force with process variables were developed using ANOVA and polynomial regression. The variation of the apparent friction coefficient was analyzed with respect to tool geometry and the cutting process. The results indicated that cutting and thrust forces increase with increasing feed rate, and decrease with increasing rake angles from negative to positive values and increasing cutting speed. A power law relationship between the apparent friction coefficient and the normal force exerted by the chip on the tool-rake face was identified, the former decreasing with an increasing normal force.

Anisotropic Cutting Force Characteristics in Milling of Maraging Steel Processed Through Selective Laser Melting

2021 ◽  
Author(s):  
Shoichi Tamura ◽  
Takashi Matsumura ◽  
Atsushi Ezura ◽  
Kazuo Mori
Keyword(s):  
Additive Manufacturing ◽  
Cutting Force ◽  
Maraging Steel ◽  
Selective Laser Melting ◽  
Cutting Forces ◽  
Manufacturing Process ◽  
Laser Scanning ◽  
Force Model ◽  
Laser Melting ◽  
Scanning Direction

Abstract Additive manufacturing process of maraging steel has been studied for high value parts in aerospace and automotive industries. The hybrid additive / subtractive manufacturing is effective to achieve tight tolerances and surface finishes. The additive process induces anisotropic mechanical properties of maraging steel, which depends on the laser scanning direction. Because anisotropy in the workpiece material has an influence on the cutting process, the surface finish and the dimension accuracy change according to the direction of the cutter feed with respect to the laser scanning direction. Therefore, the cutting parameters should be determined to control the cutting force considering material anisotropy. The paper discusses the cutting force in milling of maraging steel stacked with selective laser melting, as an additive manufacturing process. Anisotropic effect on the cutting forces is proved with the changing rate of the cutting force in milling of the workpieces stacked by repeating laser scanning at 0/90 degrees and 45/−45 degrees. The cutting forces, then, are analyzed in the chip flow models with piling up of orthogonal cuttings. The force model associates anisotropy with the shear stress on the shear plane. The changes in the cutting forces with the feed direction are discussed in the cutting tests and analysis.

Analytical Convolution Model of Cutting Forces in 3-D Ball End Milling

2001 ◽  
Author(s):  
Richard Y. Chiou ◽  
Bing Zhao
Keyword(s):  
Cutting Force ◽  
Frequency Domain ◽  
Cutting Forces ◽  
End Milling ◽  
Force Model ◽  
Three Dimensional Model ◽  
Calculation Algorithm ◽  
Ball End Milling ◽  
Convolution Model ◽  
Force Calculation

Abstract This paper presents an analytical convolution model of dynamic cutting forces in ball end milling of 3-D plane surfaces. The model takes into account the instantaneous slope on a sculptured surface to establish the chip geometry in cutting force calculation algorithm. A three-dimensional model of cutting forces in ball end milling is presented in terms of material properties, cutting parameters, machining configuration, and tool/work geometry. Based on the relationship of the local cutting force, chip load and engaged boundary, the total cutting force model is established via the angle domain convolution integration of the local forces in the feed, cross feed, axial direction, and inclination angle. The convolution integral leads to a periodic function of cutting forces in the angle domain and an explicit expression of the dynamic cutting force components in the frequency domain. Following the theoretical analysis, experimental study is discussed to illustrate the implementation procedure for force identification, and frequency domain data are presented to verify the analytical results.

Analysis of Cutting Force in Elastomer End-Milling

2017 ◽  
Vol 11 (6) ◽  
pp. 958-963
Author(s):  
Koji Teramoto ◽  
◽  
Takahiro Kunishima ◽  
Hiroki Matsumoto
Keyword(s):  
Parameter Identification ◽  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Process Models ◽  
Force Model ◽  
Cutting Force Model ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
The Stability

Elastomer end-milling is attracting attention for its role in the small-lot production of elastomeric parts. In order to apply end-milling to the production of elastomeric parts, it is important that the workpiece be held stably to avoid deformation. To evaluate the stability of workholding, it is necessary to predict cutting forces in elastomer end-milling. Cutting force prediction for metal workpiece end-milling has been investigated for many years, and many process models for end-milling have been proposed. However, the applicability of these models to elastomer end-milling has not been discussed. In this paper, the characteristics of the cutting force in elastomer end-milling are evaluated experimentally. A standard cutting force model and its parameter identification method are introduced. By using this cutting force model, measured cutting forces are compared against the calculated results. The comparison makes it clear that the standard cutting force model for metal end-milling can be applied to down milling for a rough evaluation.

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.

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