scholarly journals Accurate Modeling of Working Normal Rake Angles and Working Inclination Angles of Active Cutting Edges and Application in Cutting Force Prediction

Micromachines ◽  
2021 ◽  
Vol 12 (10) ◽  
pp. 1207
Author(s):  
Peng Li ◽  
Zhiyong Chang
Keyword(s):  
Cutting Force ◽  
High Performance ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Cutting Edge ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
Inclination Angles ◽  
Cutting Velocity ◽  
Differential Element

The normal Rake angle is an important geometric parameter of a turning tool, and it directly affects the accuracy of the cutting force prediction. In this study, an accurate model of the working normal rake angle (WNRA) and working inclination angle (WIA) is presented, including variation in the cutting velocity direction. The active cutting edge of the turning tool is discretized into differential elements. Based on the geometric size of the workpiece and the position of the differential elements, the cutting velocity direction of each differential element is calculated, and analytical expressions for the WNRA, WIA, and working side cutting edge angle are obtained for each differential element. The size of the workpiece is found to exert an effect on the WNRA and WIA of the turning tool. The WNRA and WIA are used to predict the cutting force. A good agreement between the predicted and experimental results from a series of turning experiments on GH4169 with different cutting parameters (cutting depth and feed rate) demonstrates that the proposed model is accurate and effective. This research provides theoretical guidelines for high-performance machining.

scholarly journals Precise Design of Drill Structure Based on Cutting Force Distribution Alone Cutting Edge in CFRP Drilling

2021 ◽  
Author(s):  
Xin-Yi Qiu ◽  
Peng-Nan Li ◽  
Chang-Ping Li ◽  
Qiu-Lin Niu ◽  
Shu-Jian Li ◽  
...  
Keyword(s):  
Cutting Force ◽  
Thrust Force ◽  
Rake Angle ◽  
Cutting Edge ◽  
Distribution Model ◽  
Force Distribution ◽  
Force Coefficient ◽  
Cutting Force Prediction ◽  
Drilling Performance ◽  
Step Drill

Abstract At present, the problems that need to be solved urgently in CFRP drilling are delamination and tool wear, which are closely related to the distribution of cutting force on the cutting edge. The aim of this paper is to present a method to analyze the cutting force distribution on the main cutting edge of the drill. This method applies to the analysis of the drilling performance of double point angle (DPA) drill and to optimize the step drill structure for CFRP drilling. Both of these applications prove the correctness of the analysis method. According to the calculation model of the rake angle of the main cutting edge of the twist drill and the cutting force prediction model, the distribution model of the cutting force on the main cutting edge is established. This method reveals the basic reason why the thrust force increases linearly when a single main cutting edge cuts into the workpiece. In the process of analyzing the drilling performance of the DPA drill, the edge force coefficient is used to represent the thrust force, and the application environment of the drill with a different structure is analyzed. Based on the distribution characteristics of the axial force on the main cutting edge, the step ratio of the step drill is optimized. This method can optimize the step ratio of the step drill. This method can be employed to optimize the step ratio of any structure step drill.

Probabilistic Sequential Prediction of Cutting Force Using Kienzle Model in Orthogonal Turning Process

2018 ◽  
Vol 141 (1) ◽  
Author(s):  
M. Salehi ◽  
T. L. Schmitz ◽  
R. Copenhaver ◽  
R. Haas ◽  
J. Ovtcharova
Keyword(s):  
Bayesian Inference ◽  
Cutting Force ◽  
Rake Angle ◽  
Model Verification ◽  
Force Model ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
Prior Probabilities ◽  
Orthogonal Turning ◽  
Sequential Prediction

Probabilistic sequential prediction of cutting forces is performed applying Bayesian inference to Kienzle force model. The model uncertainties are quantified using the Metropolis algorithm of the Markov chain Monte Carlo (MCMC) approach. Prior probabilities are established and posteriors of the models parameters and force predictions are completed using the results of orthogonal turning experiments. Two types of tools with chamfer (rake) angles of 0 deg and −10 deg are tested under various cutting speed and feed per revolution values. First, Bayesian inference is applied to two force models, Merchant and Kienzle, to investigate the cutting force prediction at the low feed values for the 0 deg rake angle tool. Second, the results of the posteriors of the Kienzle model parameters are used as prior probabilities of the −10 deg rake angle tool. The simulation results of the 0 deg and −10 deg tool rake angle are compared with the experiments which are obtained under other cutting conditions for model verification. Maximum prediction errors of 7% and 9% are reported for the tangential and feed forces, respectively. This indicates a good capability of the Bayesian inference for model parameter identification and cutting force prediction considering the inherent uncertainty and minimum input experimental data.

A novel mechanics model of parametric helical-end mills for 3D cutting force prediction

2011 ◽  
Vol 225 (7) ◽  
pp. 1693-1702 ◽  
Author(s):  
W Yongqing ◽  
L Haibo
Keyword(s):  
Shear Stress ◽  
Cutting Force ◽  
Phase Angle ◽  
Manufacturing Systems ◽  
Cutting Edge ◽  
Cutting Force Prediction ◽  
Average Deviation ◽  
Force Prediction ◽  
Mechanics Model ◽  
End Mills

Cutting force prediction plays an important role in modern manufacturing systems to effectively design cutters, fixtures, and machine tools. A novel mechanics model of parametric helical-end mills is systematically presented for three-dimensional (3D) cutting force prediction in the article, which is different from mechanistic approach and Oxley’s predictive machining theory in model formulation and shear stress identification process. The single-flute cutting edge and multiflute cutting edge of helical-end mills are modelled according to kinematic analysis with vector algebra. Based on Merchant’s oblique cutting theory, a new mechanics model of 3D cutting force with runout has been developed. Meanwhile, the asynchronous problem between predicted and measured curves is solved by adjusting phase angle to minimize the average deviation. After minimizing the asynchronous phase angle deviation, shear stress can be estimated directly using corresponding peak-to-peak ratio or valley-to-valley ratio of the predicted curves and the measured curves in X- and Y-directions of an arbitrary selected milling test. To assess the feasibility of the general model, over 100 milling experiments of aluminium alloy (7075) using flat-end mills and ball-end mills were conducted, respectively, and numerical tests implemented in time domain on MathWorks platform. The comparative results indicated that the predicted and the measured waveforms were quite satisfied in both pulsation pattern and period.

scholarly journals Cutting Force Prediction Models by FEA and RSM When Machining X56 Steel with Single Diamond Grit

Micromachines ◽  
2021 ◽  
Vol 12 (3) ◽  
pp. 326
Author(s):  
Lan Zhang ◽  
Xianbin Sha ◽  
Ming Liu ◽  
Liquan Wang ◽  
Yongyin Pang
Keyword(s):  
Cutting Force ◽  
Coefficient Of Friction ◽  
High Speed ◽  
Prediction Models ◽  
Pipeline Steel ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
Diamond Wire Saw

In the field of underwater emergency maintenance, submarine pipeline cutting is generally performed by a diamond wire saw. The process, in essence, involves diamond grits distributed on the surface of the beads cutting X56 pipeline steel bit by bit at high speed. To find the effect of the different parameters (cutting speed, coefficient of friction and depth of cut) on cutting force, the finite element (FEA) method and response surface method (RSM) were adopted to obtain cutting force prediction models. The former was based on 64 simulations; the latter was designed according to DoE (Design of Experiments). Confirmation experiments were executed to validate the regression models. The results indicate that most of the prediction errors were within 10%, which were acceptable in engineering. Based on variance analyses of the RSM models, it could be concluded that the depth of the cut played the most important role in determining the cutting force and coefficient the of friction was less influential. Despite making little direct contribution to the cutting force, the cutting speed is not supposed to be high for reducing the coefficient of friction. The cutting force models are instructive in manufacturing the diamond beads by determining the protrusion height of the diamond grits and the future planning of the cutting parameters.

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.

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