The prediction of cutting force in end milling titanium alloy (Ti6Al4V) with polycrystalline diamond tools

2016 ◽  
Vol 231 (1) ◽  
pp. 3-14 ◽  
Author(s):  
Wencheng Pan ◽  
Songlin Ding ◽  
John Mo
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Polycrystalline Diamond ◽  
Force Model ◽  
Machining Parameters ◽  
Diamond Tools ◽  
Cutting Coefficients ◽  
Titanium Alloy Ti6al4v

Cutting force coefficients were conventionally described as the power function of instantaneous uncut chip thickness. However, it was found that the changes in the three controllable machining parameters (cutting speed, feed and axial cutting depth) could significantly affect the values of cutting coefficients. An improved cutting force model was developed in this article based on the experimental investigation of end milling titanium alloy (Ti6Al4V) with polycrystalline diamond tools. The relationships between machining parameters and cutting force are established based on the introduction of the new cutting coefficients. By integrating the effects of varying cutting parameters in the prediction model, cutting forces and the fluctuation of cutting force in each milling cycle were calculated. Validation experiments show that the predicted peak values of cutting forces highly match the experimental results; the accuracy of the model is up to 90% in predicting instantaneous cutting forces.

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.

A Mechanistic Model of Cutting Forces in Micro-End-Milling With Cutting-Condition-Independent Cutting Force Coefficients

2008 ◽  
Vol 130 (3) ◽  
Author(s):  
Han Ul Lee ◽  
Dong-Woo Cho ◽  
Kornel F. Ehmann
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Cutting Conditions ◽  
Thickness Effect ◽  
Force Model ◽  
Cutting Force Coefficients ◽  
Force Coefficients ◽  
Micro End Milling ◽  
Cutting Mechanisms

Complex three-dimensional miniature components are needed in a wide range of industrial applications from aerospace to biomedicine. Such products can be effectively produced by micro-end-milling processes that are capable of accurately producing high aspect ratio features and parts. This paper presents a mechanistic cutting force model for the precise prediction of the cutting forces in micro-end-milling under various cutting conditions. In order to account for the actual physical phenomena at the edge of the tool, the components of the cutting force vector are determined based on the newly introduced concept of the partial effective rake angle. The proposed model also uses instantaneous cutting force coefficients that are independent of the end-milling cutting conditions. These cutting force coefficients, determined from measured cutting forces, reflect the influence of the majority of cutting mechanisms involved in micro-end-milling including the minimum chip-thickness effect. The comparison of the predicted and measured cutting forces has shown that the proposed method provides very accurate results.

Dynamic cutting force prediction for micro end milling considering tool vibrations and run-out

2018 ◽  
Vol 233 (7) ◽  
pp. 2248-2261 ◽  
Author(s):  
Xuewei Zhang ◽  
Tianbiao Yu ◽  
Wanshan Wang
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Chip Thickness ◽  
Milling Process ◽  
Force Model ◽  
Dynamic Cutting Force ◽  
Micro End Milling ◽  
Tool Vibrations ◽  
End Milling Process

An accurate prediction of cutting forces in the micro end milling, which is affected by many factors, is the basis for increasing the machining productivity and selecting optimal cutting parameters. This paper develops a dynamic cutting force model in the micro end milling taking into account tool vibrations and run-out. The influence of tool run-out is integrated with the trochoidal trajectory of tooth and the size effect of cutting edge radius into the static undeformed chip thickness. Meanwhile, the real-time tool vibrations are obtained from differential motion equations with the measured modal parameters, in which the process damping effect is superposed as feedback on the undeformed chip thickness. The proposed dynamic cutting force model has been experimentally validated in the micro end milling process of the Al6061 workpiece. The tool run-out parameters and cutting forces coefficients can be identified on the basis of the measured cutting forces. Compared with the traditional model without tool vibrations and run-out, the predicted and measured cutting forces in the micro end milling process show closer agreement when considering tool vibrations and run-out.

Modeling and Simulation of Cutting Forces in Side Milling

2016 ◽  
Vol 693 ◽  
pp. 843-849
Author(s):  
An Hai Li ◽  
Jun Zhao ◽  
He Lin Pan ◽  
Zhao Chao Gong
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Milling Process ◽  
Force Model ◽  
Machining Parameters ◽  
Machining Time ◽  
Side Milling ◽  
Force Coefficients ◽  
Solid Carbide ◽  
Edge Force

In order to acquire high machining quality and minimum machining time, cutting forces are usually modeled to understand the milling process, simulate or predict cutting forces, and optimize the machining parameters. In this paper, side milling tests were conducted on superalloy Inconel 718 with a solid carbide end mill, and the cutting forces vs. cutting time were measured. The average cutting forces were extracted from the measured instantaneous cutting forces under different feed rates of experiments, and the components of the shear forces and edge forces were determined by using the linear regression of the experimental data. The cutting force coefficients, including shear force coefficients and edge force coefficients, were identified. In addition, the algorithms of the mathematical model were implemented in Matlab. The predicted cutting forces were in good agreement with the experimentally measured forces, and the validation of the cutting force model was demonstrated.

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.

Convolution Analysis of Milling Force Pulsation

1994 ◽  
Vol 116 (1) ◽  
pp. 17-25 ◽  
Author(s):  
J.-J. Junz Wang ◽  
S. Y. Liang ◽  
W. J. Book
Keyword(s):  
Cutting Force ◽  
Density Function ◽  
Cutting Forces ◽  
End Milling ◽  
Chip Thickness ◽  
Closed Form Expression ◽  
Thickness Variation ◽  
Depth Of Cut ◽  
Force Model ◽  
Frequency Multiplication

This paper presents the establishment of a closed form expression for the dynamic forces as explicit functions of cutting parameters and tool/workpiece geometry in milling processes. Based on the existing local cutting force model, the generation of total cutting forces is formulated as the angular domain convolution of three cutting process component functions, namely the elementary cutting function, the chip width density function, and the tooth sequence function. The elemental cutting force function is related to the chip formation process in an elemental cutting area and it is characterized by the chip thickness variation, and radial cutting configuration. The chip width density function defines the chip width per unit cutter rotation along a cutter flute within the range of axial depth of cut. The tooth sequence function represents the spacing between flutes as well as their cutting sequence as the cutter rotates. The analysis of cutting forces is extended into the Fourier domain by taking the frequency multiplication of the transforms of the three component functions. Fourier series coefficients of the cutting forces are shown to be explicit algebraic functions of various tool parameters and cutting conditions. Numerical simulation results are presented in the frequency domain to illustrate the effects of various process parameters. A series of end milling experiments are performed and their results discussed to validate the analytical model.

scholarly journals Cutting Force Modeling and Optimization in 3D Plane Surface Machining

1999 ◽  
Author(s):  
Hsi-Yung (Steve) Feng ◽  
Ning Su
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Plane Surface ◽  
Mechanistic Modeling ◽  
Surface Finishing ◽  
Force Model ◽  
Cutting Force Model ◽  
Ball End Milling ◽  
Finishing Machining

Abstract The prediction and optimization of cutting forces in the finishing machining of 3D plane surfaces using ball-end milling are presented in this paper. The cutting force model is developed based on the mechanistic modeling approach. This improved model is able to accurately predict the cutting forces for non-horizontal and cross-feed cutter movements typical in 3D finishing ball-end milling. Optimization of the cutting forces is used to determine both the tool path and the maximum feed rate in 3D plane surface finishing machining. The objective is to achieve highest machining efficiency and to ensure product quality. Experimental results have shown that the cutting force model gives excellent predictions of cutting forces in 3D finishing ball-end milling. The feasibility of the integrated process planning method has been demonstrated through the establishment of optimized process plans for the finishing machining of 3D plane surfaces.

Identification of Polynomial Cutting Coefficients for a Dual-Mechanism Ball-end Milling Force Model

2019 ◽  
Vol 13 (3) ◽  
pp. 232-240
Author(s):  
Zhixin Feng ◽  
Meng Liu ◽  
Guohe Li
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Least Square ◽  
Force Model ◽  
Cutting Force Coefficients ◽  
Milling Force ◽  
Ball End Milling ◽  
Force Coefficients ◽  
Cutting Coefficients ◽  
Milling Force Model

Background: Calibration of cutting coefficients is the key content in modeling a mechanistic cutting force model. Generally, in modeling cutting force for ball end milling, the tangent, radial and binormal cutting force coefficients are each considered as a polynomial, respectively. This fact is due to the dependency between the cutting force coefficients and the cutting edge inclination angle which is variable in ball-end mills. Objective: This paper presents an approach to determine the polynomial cutting force coefficients. Methods: In this approach, the cutting force coefficients are expressed as explicit linear equations about the average slotting forces. After analysis of the least square regression method which is utilized in the cutting coefficients evaluation, the principle of cutting parameters choice in calibration experiment and the relationship between the order of polynomial and the number of experiments are presented. Besides, a lot of patents on identification of polynomial cutting coefficients for milling force model were studied. Results: Finally, a series of semi-slotting verification cutting tests were arranged, the measured force agrees well with the predicted force, which demonstrates the effectiveness of this approach. Conclusion: Based on the calibration method proposed in this paper, the cutting coefficients can be determined through (m+2) slotting experiments for m-degree shearing coefficients polynomial theoretically.

Cutting Characteristics of Binderless Diamond Tools in High-Speed Turning of Ti-6Al-4V – Availability of Single-Crystal and Nano-Polycrystalline Diamond –

2016 ◽  
Vol 10 (3) ◽  
pp. 411-419
Author(s):  
Abang Mohammad Nizam Abang Kamaruddin ◽  
◽  
Akira Hosokawa ◽  
Takashi Ueda ◽  
Tatsuaki Furumoto ◽  
...  
Keyword(s):  
Titanium Alloy ◽  
Single Crystal ◽  
Cutting Force ◽  
High Speed ◽  
Diamond Tool ◽  
Cutting Temperature ◽  
Polycrystalline Diamond ◽  
Water Soluble ◽  
Diamond Tools ◽  
Single Crystal Diamond

In this study, the tool performance of two types of binderless diamond tools – single-crystal diamond (SCD) and nano-polycrystalline diamond (NPD) – is investigated in the high-speed cutting of titanium alloy (Ti-6Al-4V) with a water-soluble coolant. The NPD tool allows for a larger cutting force than the SCD tool by dulling of the cutting edge, despite NPD being harder than SCD. This large cutting force and the very low thermal conductivity of NPD yield a high cutting temperature above 500°C, which promotes the adhesion of the workpiece to the tool face, thereby increasing tool wear. Based on the morphology of the tool edge without scratch marks and the elemental analysis by energy-dispersive X-ray spectroscopy (EDX) of both the flank face and the cutting chips, diffusion-dissolution wear is determined to be the dominant mechanism in the diamond tool. A thin TiC layer seems to be formed in the boundary between the diamond tool and the titanium alloy at high temperatures; this is removed by the cutting chips.

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