Investigation of Tool Deflection of Solid Carbide End Mill in Cutting Process

2012 ◽  
Vol 163 ◽  
pp. 95-99 ◽  
Author(s):  
Qiong Wu ◽  
Yi Du Zhang ◽  
Xiang Sheng Gao ◽  
Lin Fang
Keyword(s):  
Cutting Process ◽  
Beam Deflection ◽  
Work Piece ◽  
Force Model ◽  
Tool Deflection ◽  
End Mill ◽  
Element Analysis ◽  
Solid Carbide ◽  
Deflection Theory ◽  
Milling Force Model

Tool deflection is one of the important influencing factors for surface roughness and surface integrity of work piece in cutting process. The excessive deflection even causes seriously defects of work piece or failures of tool. This paper gives theory analysis and mathematic method to predict the tool deflection by means of the cantilever beam deflection theory. Based on modeling of 3-dimmsion milling force model, the finite element analysis has been performed for calculation of tool deflection. The experiment of tool deflection of solid end mill is performed to compare simulation and theory. Results show the correction and reliability of research method. It lays a foundation for fast calculation of tool deflection and optimization of milling parameters.

Chatter Stability Prediction of Cutting Process With Process Damping Utilizing Finite Element Analysis

2020 ◽  
Author(s):  
Norikazu Suzuki ◽  
Tomoki Nakanomiya ◽  
Eiji Shamoto
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Vibration Amplitude ◽  
Cutting Process ◽  
Force Model ◽  
Chatter Stability ◽  
Chatter Vibration ◽  
Damping Force ◽  
Element Analysis ◽  
Process Damping

Abstract This paper presents a new approach to predict chatter stability in cutting considering process damping. Traditional chatter stability analysis methods enable to predict stable or unstable conditions. Under unstable conditions, the chatter vibration can increase theoretically infinitely. However, chatter vibration is damped at a certain amplitude in real process due to process damping, i.e., the cutting process is stabilized by means of tool flank face contact to the machined surface. In order to consider the influence of the process damping, a simple process damping force model is introduced. The process damping force is assumed to be proportional to the structural displacement. The process damping coefficient is a function of the vibration amplitude and the wavelength. In order to identify the coefficients, a series of finite element analysis is conducted in the present study. Identified coefficients are introduced into the conventional zero-order-solution in frequency domain. The proposed model calculates chatter stability limit assuming process damping with finite amplitude. Hence, this analysis enables to estimate the amplitude-dependent quasi-stable conditions. Analytical results for thee face turning operation demonstrated influence of process damping effect on resultant vibration amplitude quantitatively.

Force Modeling of Five-Axis Microball-End Milling

2015 ◽  
Vol 3 (3) ◽  
Author(s):  
Chi Xu ◽  
James Zhu ◽  
Shiv G. Kapoor
Keyword(s):  
End Milling ◽  
Elastic Recovery ◽  
Chip Thickness ◽  
Force Model ◽  
End Mill ◽  
Data Simulation ◽  
Force Modeling ◽  
Static Indentation ◽  
Five Axis ◽  
Milling Force Model

This paper presents a five-axis ball-end milling force model that is specifically tailored to microscale machining. A composite cutting force is generated by combining two force contributions from a shearing/ploughing slip-line (SL) field model and a quasi-static indentation (ID) model. To fully capture the features of microscale five-axis machining, a unique chip thickness algorithm based on the velocity kinematics of a ball-end mill is proposed. This formulation captures intricate tool trajectories as well as readily allows the integration of runout and elastic recovery effects. A workpiece updating algorithm has also been developed to identify tool–workpiece engagement. As a dual purpose, historical elastic recovery is stored locally on the meshed workpiece surface in vector form so that the directionality of elastic recovery is preserved for future time increments. The model has been validated through a comparison with five-axis end mill force data. Simulation results show reasonably accurate replication of end milling cutting forces with minimal experimental data fitting.

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.

Finite Element Simulation of the Orthogonal Cutting Based on Abaqus

2013 ◽  
Vol 821-822 ◽  
pp. 1410-1413 ◽  
Author(s):  
Xue Bin Liu ◽  
Xi Bin Wang ◽  
Chong Ning Li ◽  
San Peng Deng
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Orthogonal Cutting ◽  
Element Model ◽  
Friction Model ◽  
Cutting Process ◽  
Work Piece ◽  
Conduction Model ◽  
Element Analysis ◽  
Element Simulation

In view of orthogonal cutting, finite element simulation geometry is built. the friction model, thermal conduction model and chip separation model are established between chip and tool using Abaqus which is a finite element analysis software. Through a specific example, two-dimensional finite element model have been established, simulating the cutting process stress distribution of the work piece surface is also obtained during processing. While simulation analyzes the relationship between the rake angle and shear angle, the results of simulation and experiment are basically the same, thus further verify the credibility of Abaqus simulation results on orthogonal cutting, and the feasible is also proved of obtaining cutting data by the use of Abaqus simulation cutting process.

scholarly journals The Predictive Research of Dynamic Milling Force Based on Data Mining

2021 ◽  
Author(s):  
Lan Jin ◽  
Xinlei Zeng ◽  
Shiqi Lu ◽  
Liming Xie ◽  
Xuefeng Zhang
Keyword(s):  
Data Mining ◽  
Rbf Neural Network ◽  
Cutting Parameters ◽  
Production Quality ◽  
Work Piece ◽  
Force Model ◽  
Milling Force ◽  
Using Data ◽  
Milling Force Model ◽  
Predictive Research

Abstract In this paper, surface accuracy of the work-piece was improved by mining large amounts of machining data and obtaining potentially valuable information. By using data mining technology, a dynamic milling force prediction model has been established to keep with its working. The model was developed by a combination of Regression Analysis and RBF Neural Network. The internal relation of the data were analyzed in this study, such as milling force, cutting parameters, temperature, vibration and surface quality et.al, and the methods of Cluster Analysis and Correlation Analysis was used to extract and induct dynamic milling force variations on the effects with different situations. The results suggest that the proposed dynamic milling force model had a better prediction effect, which ensure production quality, reduce the occurrence of chatter and provide a more accurate basis for selecting process parameters.

Cutting Process Dynamics Simulation for Machine Tool Structure Design

1986 ◽  
Vol 108 (2) ◽  
pp. 68-74 ◽  
Author(s):  
S. J. Lee ◽  
S. G. Kapoor
Keyword(s):  
Finite Element ◽  
Machine Tool ◽  
Structural Model ◽  
Face Milling ◽  
Cutting Process ◽  
Force Model ◽  
Milling Force ◽  
Process Dynamics ◽  
Machine Tool Structure ◽  
Milling Force Model

A methodology to simulate the real cutting process dynamics using a finite element structural model and a mechanistic face milling force model is proposed. While the finite element structural model provides an analytic way to assess structural dynamic characteristics, the mechanistic face milling force model calculates the time histories of cutting forces taking many cutting process parameters into consideration and acts as forcing functions to the structural model. The methodology is verified through experimentation. The effects of structural parameters and cutting process parameters on the dynamic behavior of the machine tool structure are also studied. The results indicate that the proposed methodology can greatly enhance the machine tool design process.

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.

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.

Research on Solid Modeling and a Different Mode of Loading with Finite Element Analysis for Flat End Mill

2012 ◽  
Vol 500 ◽  
pp. 550-555
Author(s):  
Qing Shan Liu ◽  
Guang Yu Tan ◽  
Guang Jun Liu ◽  
Yan Li Su ◽  
Guang Hui Li
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Cutting Force ◽  
High Speed ◽  
Force Model ◽  
Shear Stresses ◽  
End Mill ◽  
Element Analysis ◽  
High Speed Cutting ◽  
Loading Mode

This work aims to investigate parameterized modeling and a different mode of loading with finite element analysis for flat end mill. A loading mode is chosen according to the cutting force model of overall end mills. Normal and shear stresses which calculate from the cutting force experiments are loaded on the rack face of flat end mill. The stress distribution of end mill in high-speed cutting is obtained by finite element analysis. It is shown that the maximum stress is located at major flank face near the tool tip, rather than the nose of tool and the chisel edge. It shows the tool breakage mechanism in the local region. In the end, we compared the finite element analysis results with the experiment ones. It indicates that the analysis results agree well with the experimental data. Therefore, the proposed loading mode is available.

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