Determining cutting force coefficients from instantaneous cutting forces in ball end milling

2016 ◽  
Vol 18 (5/6) ◽  
pp. 552
Author(s):  
Mithilesh K. Dikshit ◽  
Asit Baran Puri ◽  
Atanu Maity ◽  
Amit Jyoti Banarjee
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Cutting Force Coefficients ◽  
Ball End Milling ◽  
Force Coefficients

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.

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.

3D Ball-End Milling Force Model Using Instantaneous Cutting Force Coefficients

2005 ◽  
Vol 127 (1) ◽  
pp. 1-12 ◽  
Author(s):  
Jeong Hoon Ko ◽  
Dong-Woo Cho
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Cutting Conditions ◽  
Force Model ◽  
Cutting Force Model ◽  
Cutting Force Coefficients ◽  
Milling Force ◽  
Ball End Milling ◽  
Force Coefficients ◽  
Instantaneous Cutting Force Coefficients

Application of a ball-end milling process model to a CAD/CAM or CAPP system requires a generalized methodology to determine the cutting force coefficients for different cutting conditions. In this paper, we propose a mechanistic cutting force model for 3D ball-end milling using instantaneous cutting force coefficients that are independent of the cutting conditions. The uncut chip thickness model for three-dimensional machining considers cutter deflection and runout. An in-depth analysis of the characteristics of these cutting force coefficients, which can be determined from only a few test cuts, is provided. For more accurate cutting force predictions, the size effect is also modeled using the cutter edge length of the ball-end mill and is incorporated into the cutting force model. This method of estimating the 3D ball-end milling force coefficients has been tested experimentally for various cutting conditions.

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.

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