A Frequency Domain Force Model With Shearing and Ploughing Mechanisms for a Generalized Helical End Mill

Manufacturing ◽  
2002 ◽  
Author(s):  
J.-J. Junz Wang ◽  
C. M. Zheng
Keyword(s):  
Frequency Domain ◽  
Fourier Coefficients ◽  
Milling Process ◽  
Domain Model ◽  
Force Model ◽  
End Mill ◽  
Milling Force ◽  
End Mills ◽  
Milling Force Model ◽  
Chip Load

For a generalized helical end mill, this paper presents a frequency domain force model considering the ploughing as well as the shearing mechanisms. The differential chip load and the corresponding cutting forces are first formulated through differential geometry for a general helical cutting edge. The differential cutting force is assumed to be a linear function of the chip load with a proportional shearing force and a constant ploughing force. The total milling force in the angle domain is subsequently composed through convolution integration and analyzed by Fourier analysis. The frequency domain model has the parameters of a general milling process all integrated in a single framework with their roles clearly defined so that Fourier coefficients of the milling force can be obtained for any analytically definable helical cutter. Applications are illustrated for three common helical cutters: the cylindrical, taper, and ball end mills. Furthermore, as an inverse application, a linear algebraic equation is formulated for the identification of six cutting constants from the average forces of two slot milling tests. Demonstration and verification of the milling force model as well as the identification of cutting constants are carried out through experiments with three types of milling cutters.

Modeling and Simulation of Milling Force in Virtual Numerical Control Milling Process

2008 ◽  
Vol 392-394 ◽  
pp. 697-702
Author(s):  
Xiu Lin Sui ◽  
Jia Tai Zhang ◽  
Jiang Hua Ge ◽  
Ya Ping Wang ◽  
H. Yuan
Keyword(s):  
Modeling And Simulation ◽  
Chip Thickness ◽  
Milling Process ◽  
Cutting Edge ◽  
Numerical Control ◽  
Force Model ◽  
End Mill ◽  
Ball End Mill ◽  
Milling Force ◽  
Milling Force Model

A parameter equation based on cutting edge of ball-end mill is set up by analyzing the parameters of ball-end mill influence the milling force in virtual NC milling process. The relationship among elemental cutting force, instantaneous radial chip thickness and cutting edge length is analyzed, and the dynamic milling force of ball-end mill at arbitrary feed direction is established. The milling force parameter model by quadratic regression equation in different cutting conditions is built. Through experiments in NC machining center and using orthogonal combination and principal components analysis, the regression coefficients are calculated. The correctness of milling force model is testified by experiments. All these can provide theoretical basis for physics modeling and simulation of virtual numerical control milling.

Milling force model for asymmetric end-mills during high-feed milling on AISI-P20

2021 ◽  
pp. 1-8
Author(s):  
Diego Russo ◽  
Gorka Urbicain ◽  
Antonio J. Sánchez Egea ◽  
Alejandro Simoncelli ◽  
Daniel Martinez Krahmer
Keyword(s):  
Force Model ◽  
Milling Force ◽  
Aisi P20 ◽  
High Feed ◽  
End Mills ◽  
Milling Force Model

Research on Error Compensation of Corner Milling Process Based on Milling Force Prediction

2014 ◽  
Vol 800-801 ◽  
pp. 761-765
Author(s):  
Hui Nan Shi ◽  
Fu Gang Yan ◽  
Yun Peng Ding ◽  
Xian Li Liu ◽  
Rui Zhang
Keyword(s):  
Error Compensation ◽  
Chip Thickness ◽  
Milling Process ◽  
Force Model ◽  
Deformation Model ◽  
Milling Force ◽  
Element Analysis ◽  
The Finite Element Analysis ◽  
Flexible Deformation ◽  
Milling Force Model

In cavity die corner-machining, tool flexible deformation caused by the milling force resulting in the surface error, a method of off-line error compensation is put forward. Instantaneous chip thickness model and the corner milling force model is established based on differential and the characteristics of the corner. Combining the theory of cantilever beam and the finite element analysis, cutting tool elastic deformation model is established.

Analysis to Milling Force Base on AdvantEdge Finite Element Analysis

2014 ◽  
Vol 981 ◽  
pp. 895-898
Author(s):  
Fu Cai Zhang ◽  
Qing Wang ◽  
Ru Yang
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Simulation Analysis ◽  
Cutting Parameters ◽  
Milling Process ◽  
Force Model ◽  
Cnc Milling ◽  
Milling Force ◽  
Element Analysis ◽  
Milling Force Model

Aiming at NC milling processing simulation problem, a ball-end cutter milling force model is established, the numerical simulation analysis of aluminum alloy AL2024 milling process is conducted by using the finite element analysis software AdvantEdge finite element analysis. Focus on the Milling force simulation, the size of the milling force is obtained by simulating calculation. Using the same cutting parameters for milling experiment, the results show that simulation analysis of the cutting force values ​​are in good agreement with the experimental results，the milling force model prior established is correct. The research laid a foundation for the perfect CNC milling simulation system.

CAD Assisted Adaptive Control for Milling

1991 ◽  
Vol 113 (3) ◽  
pp. 444-450 ◽  
Author(s):  
A. Spence ◽  
Y. Altintas
Keyword(s):  
Adaptive Control ◽  
Control Method ◽  
Adaptive Controller ◽  
Milling Process ◽  
Force Model ◽  
Online Information ◽  
Geometric Information ◽  
Milling Force ◽  
Part Geometry ◽  
Milling Force Model

A milling process adaptive control method, which prevents force overshoots during sudden part geometry changes, has been developed by providing online information to the controller from the part’s CAD representation. A first-order discrete model structure to represent the milling process for adaptive control was analytically developed and experimentally identified. Provided with geometric information obtained from the part’s CAD model, and utilizing the milling force model, the adaptive controller predicts the maximum cutting force expected in advance of dangerous immersion changes. The technique permits the controller to anticipate the changing workpiece in time to eliminate force overshoots which would otherwise break the tool, yet adaptive control at all times remains active to respond to other geometrical and material variations. Simulation and experimental results are presented to confirm the viability of the proposed method.

Coupled thermal and mechanical analyses of micro-milling Inconel 718

2018 ◽  
Vol 233 (4) ◽  
pp. 1112-1126 ◽  
Author(s):  
Xiaohong Lu ◽  
Hua Wang ◽  
Zhenyuan Jia ◽  
Yixuan Feng ◽  
Steven Y Liang
Keyword(s):  
Inconel 718 ◽  
Cutting Temperature ◽  
Milling Process ◽  
Micro Milling ◽  
Force Model ◽  
Temperature Model ◽  
Milling Force ◽  
Mechanical Coupling ◽  
Milling Forces ◽  
Milling Force Model

Micro-milling forces, cutting temperature, and thermal–mechanical coupling are the key research topics about the mechanism of micro-milling nickel-based superalloy Inconel 718. Most current analyses of thermal–mechanical coupling in micro-milling are based on finite element or experimental methods. The simulation is not conducive to revealing the micro-milling mechanism, while the results of experiments are only valid for certain machine tool and workpiece material. Few analytical coupling models of cutting force and cutting temperature during micro-milling process have been proposed. Therefore, the authors studied coupled thermal–mechanical analyses of micro-milling Inconel 718 and presented a revised three-dimensional analytical model of micro-milling forces, which considers the effects of the cutting temperature and the ploughing force caused by the arc of cutting edge during shear-dominant cutting process. Then, an analytical cutting temperature model based on Fourier’s law is presented by regarding the contact area as a moving finite-length heat source. Coupling calculation between micro-milling force model and temperature model through an iterative process is conducted. The novelty is including cutting temperature into micro-milling force model, which simulates the interaction between cutting force and cutting temperature during micro-milling process. The established model predicts both micro-milling force and temperature. Finally, experiments are conducted to verify the accuracy of the proposed analytical method. Based on the coupled thermal–mechanical analyses and experimental results, the authors reveal the effects of cutting parameters on micro-milling forces and temperature.

Modeling of dynamic milling forces considering the interlaminar effect during milling multidirectional CFRP laminate

2020 ◽  
pp. 073168442097176
Author(s):  
Fuji Wang ◽  
Guangjian Bi ◽  
Fuda Ning
Keyword(s):  
Superposition Principle ◽  
Milling Process ◽  
Force Model ◽  
Milling Force ◽  
Cfrp Laminate ◽  
Near Net Shape ◽  
Milling Forces ◽  
Milling Force Model ◽  
First Time

The milling process is always required to achieve dimensional tolerance for the near-net-shape carbon fiber reinforced polymer (CFRP) parts. However, delamination and cracking are inevitably induced in milling CFRP due to the excessive milling forces. The milling forces should be thereby well controlled to reduce damages of CFRP parts. Developing a theoretical milling force model is an effective approach to understand the mechanism of milling force generation. Recent studies have established the predictive models; however, the interlaminar effect impacting the material removal process is not considered during milling multidirectional CFRP laminate, limiting the predictive model accuracy. In this work, a model of dynamic milling force for multidirectional CFRP laminate was developed by considering the interlaminar effect for the first time. The specific cutting energy predicted by the artificial neural network methodology was employed to calculate the milling forces during milling a single CFRP layer. Meantime, the support of the layer was enhanced due to the interlaminar effect, and the correction coefficients for each type of support were proposed to reflect the role of this effect. Then, the overall milling forces for multidirectional CFRP laminate can be obtained via the superposition principle, which agreed well with the experimentally measured results.

Simulation and Optimal Selection of Pitch Angles Distribution for Variable Pitch Angles Helix End Mills

2010 ◽  
Vol 443 ◽  
pp. 285-290
Author(s):  
Pan Ling Huang ◽  
Jian Feng Li ◽  
Jie Sun
Keyword(s):  
Cutting Parameters ◽  
Force Model ◽  
Optimal Selection ◽  
Milling Force ◽  
Frequency Spectra ◽  
Variable Pitch ◽  
End Mills ◽  
Milling Forces ◽  
Milling Force Model ◽  
Selection Of

In the paper, a static milling force model for variable pitch mills was built, and the milling forces were simulated. The resultant force and its frequency spectra of variable pitch mills were analyzed compared with that of uniform pitch mills. It is shown that the standard deviation (SD) of frequency spectra amplitudes for variable pitch mills is extremely lower than that of uniform pitch mills. Through simulation for SD of frequency spectra amplitudes affected by the different cutting parameters, a pitch angles distribution of variable pitch helix end mills with lower SD of frequency spectra amplitudes was selected.

Milling Force Modeling of Formed Milling Cutter for Turnout Processing and Experiment Validation

2012 ◽  
Vol 538-541 ◽  
pp. 921-926
Author(s):  
Li Gang Cai ◽  
Fang Yuan Pu ◽  
Yong Sheng Zhao
Keyword(s):  
Process Parameters ◽  
Metal Cutting ◽  
Milling Process ◽  
Force Model ◽  
Processing Quality ◽  
Milling Force ◽  
Milling Cutter ◽  
Study Results ◽  
Milling Force Model

Turnout is one of the key components of high-speed railway, which directly affects the maximum lateral allowable speed. The formed milling cutters are usually used in the processing of turnout, and the milling force is an active factor in the milling process which affects the functions of the machine tool and the enactment of process parameters, then the processing quality of turnouts is affected. In the paper, the theoretical milling force model for formed milling cutter is built based on the theory of metal cutting, and the working profile of curved switch rail is chosen as processing object in the milling process experiments, the validity of the milling force model is verified, The study results will provide theoretical basis for tool machine design and process parameters selection, and ensuring the processing quality of turnout.

Analysis on Milling Force Based on AdvantEdge FEM

2013 ◽  
Vol 300-301 ◽  
pp. 253-260 ◽  
Author(s):  
Xiu Lin Sui ◽  
Ru Yang ◽  
Qian Wang ◽  
Xin Ling Zhao
Keyword(s):  
Simulation Analysis ◽  
Cutting Parameters ◽  
Milling Process ◽  
Force Model ◽  
Cnc Milling ◽  
Milling Force ◽  
Element Analysis ◽  
Nc Milling ◽  
Simulation Problem ◽  
Milling Force Model

Aiming at NC milling processing simulation problem, a ball-end cutter milling force model is established, the numerical simulation analysis of aluminum alloy AL2024 milling process is conducted by using the finite element analysis software AdvantEdge FEM. Focus on the Milling force simulation, the size of the milling force is obtained by simulating calculation. Using the same cutting parameters for milling experiment, the results show that simulation analysis of the cutting force values are in good agreement with the experimental results，the milling force model prior established is correct. The research laid a foundation for the perfect CNC milling simulation system.

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