scholarly journals Stability analysis of milling with variable pitch tools considering the variable cutting force coefficients with spindle speed

2016 ◽  
Author(s):  
Gang Jin ◽  
Zhanjie Li ◽  
Jianxin Han ◽  
Hua Li
Keyword(s):  
Stability Analysis ◽  
Cutting Force ◽  
Spindle Speed ◽  
Cutting Force Coefficients ◽  
Variable Pitch ◽  
Force Coefficients

Estimating Cutting Force Coefficients in High-Speed Low-Radial-Immersion Milling Processes

2014 ◽  
Author(s):  
Josiah A. Bryan ◽  
Roger C. Fales
Keyword(s):  
Stability Analysis ◽  
Cutting Force ◽  
High Speed ◽  
Milling Process ◽  
Model Parameters ◽  
Tool Deflection ◽  
Chatter Stability ◽  
Cutting Force Coefficients ◽  
Force Coefficients ◽  
Low Radial Immersion

A high-speed milling system is considered, which is prone to chatter vibration, a stability condition dependent on system parameters (e.g., cutting force coefficients). This work is motivated by the need for model parameters which can be used in stability analysis. An Extended Kalman Filter (EKF) is proposed to estimate cutting force coefficients for each tooth in a low-radial-immersion milling process to aid chatter stability prediction. The proposed EKF utilizes tool deflection measurements and no force measurements. The model used in the EKF is found to be observable, a quality required to achieve valid state estimations. Running the EKF with experimental tool deflection measurements produces estimates of cutting force coefficients that result in good correlation between simulation (using the estimated coefficients) and experiment. Such an EKF may help customize chatter stability analysis to any particular tool-workpiece system.

The identification of the cutting force coefficients for ball-end finish milling

2019 ◽  
Vol 102 (9-12) ◽  
pp. 4121-4135
Author(s):  
Xiaojun Lin ◽  
Gang Wu ◽  
Yun Zhang ◽  
Tong Cui ◽  
Bo Zhang ◽  
...  
Keyword(s):  
Cutting Force ◽  
Cutting Force Coefficients ◽  
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.

scholarly journals A combination method of the theory and experiment in determination of cutting force coefficients in ball-end mill processes

2015 ◽  
Vol 2 (4) ◽  
pp. 233-247 ◽  
Author(s):  
Yung-Chou Kao ◽  
Nhu-Tung Nguyen ◽  
Mau-Sheng Chen ◽  
Shyh-Chour Huang
Keyword(s):  
Cutting Force ◽  
Experimental Method ◽  
Linear Function ◽  
Cutting Forces ◽  
Cutting Conditions ◽  
End Mill ◽  
Ball End Mill ◽  
Cutting Force Coefficients ◽  
Force Coefficients

Abstract In this paper, the cutting force calculation of ball-end mill processing was modeled mathematically. All derivations of cutting forces were directly based on the tangential, radial, and axial cutting force components. In the developed mathematical model of cutting forces, the relationship of average cutting force and the feed per flute was characterized as a linear function. The cutting force coefficient model was formulated by a function of average cutting force and other parameters such as cutter geometry, cutting conditions, and so on. An experimental method was proposed based on the stable milling condition to estimate the cutting force coefficients for ball-end mill. This method could be applied for each pair of tool and workpiece. The developed cutting force model has been successfully verified experimentally with very promising results. Highlights By investigation of the stable cutting conditions in milling process, the linear function of average cutting force and feed per flute was successfully verified. A combined theoretical-experimental method was proposed with an effective model for the determination of cutting force coefficients in ball-end mill process.

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