Experimental Study and Modeling of Milling Force during High-Speed Milling of SiCp/Al Composites Using Regression Analysis

2011 ◽  
Vol 188 ◽  
pp. 3-8
Author(s):  
Shu Tao Huang ◽  
X.L. Yu ◽  
Li Zhou
Keyword(s):  
Regression Analysis ◽  
Feed Rate ◽  
High Speed ◽  
Volume Fraction ◽  
Linear Regression Analysis ◽  
Force Model ◽  
Milling Force ◽  
High Speed Milling ◽  
Milling Forces ◽  
Milling Force Model

SiCp/Al composites with high volume fraction and large particles are very difficult to machine. In this present study, high-speed milling experiments were carried out on the SiCp/Al composites by the three factors-levels orthogonal experiment method, and multiple linear regression analysis was employed to establish milling force model. The results show that the milling forces decrease with the increasing of the milling speed or increase with the increasing of the feed rate and depth of milling. The influence of milling depth on the milling forces in directions of x, y is the most significant, while the influence of the feed rate on the z-milling forces are the most significant. The calculation values from the milling force model are consistent with the experimental values. The results will provide a reliable theoretical guidance for milling of SiCp/Al composites, and it is feasible to predict the milling force during the milling of SiCp/Al by using this model.

Transient Dynamic Analysis of the Matching of Lengthened Shrink-Fit Holder and Cutter in High-Speed Milling

2010 ◽  
Vol 97-101 ◽  
pp. 1819-1822 ◽  
Author(s):  
Hou Ming Zhou ◽  
Jian Xin Deng ◽  
Zhen Yu Zhao ◽  
Shi Ping Yang
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
Back Propagation ◽  
Force Model ◽  
Milling Force ◽  
Transient Dynamic Analysis ◽  
High Speed Milling ◽  
Transient Dynamic ◽  
Shrink Fit ◽  
Milling Force Model

Finite element model of the matching of lengthened shrink-fit holder (LSFH) and cutting tool is established and a milling force model is developed to predict the transient milling force exactly using back propagation neural network (BPNN). Subsequently, the transient dynamic characteristic of matching of LSFH and cutting tool is analyzed and the simulation result is obtained. Finally, the simulation result is verified with practical measurement and the results fit very well. The studies are important to optimum design and select the lengthened shrink-fit holder in high speed milling.

Study on High-Speed Milling Force of SiCp/Al Matrix Composite

2013 ◽  
Vol 690-693 ◽  
pp. 338-341
Author(s):  
Long Xin ◽  
Jun Juan Lv
Keyword(s):  
Particle Size ◽  
Matrix Composite ◽  
Feed Rate ◽  
High Speed ◽  
Volume Fraction ◽  
Force Measurement ◽  
Milling Force ◽  
High Speed Milling ◽  
Al Matrix Composite ◽  
Al Matrix

On the condition of some milling depth and feed rate, By means of high-speed milling force measurement of SiCp/Al matrix composite, the rule for impact of milling speed on milling force is revealed successfully. In some range of milling speed, when SiCp/Al is high-speed milled, the milling force is lowered with increase of milling speed. Furthermore, the experiment also show that the optimal milling speed should be adjusted between 200 and 260 m/min for the SiCp/Al matrix composite with 56% volume fraction and particle size of 60μm.

Study on Milling Force of High Volume Fraction SiCp/Al Composites with Ultrasonic Longitudinal and Torsional Vibration High Speed Milling

2014 ◽  
Vol 910 ◽  
pp. 114-117 ◽  
Author(s):  
Dao Hui Xiang ◽  
Guang Bin Yang ◽  
Song Liang ◽  
Yan Feng Wang ◽  
Qiang Qin
Keyword(s):  
Torsional Vibration ◽  
High Speed ◽  
Volume Fraction ◽  
Fold Increase ◽  
High Volume ◽  
High Volume Fraction ◽  
Milling Force ◽  
High Speed Milling ◽  
Milling Method ◽  
Milling Forces

High volume fraction SiCp/Al composites were milled in ultrasonic longitudinal and torsional vibration high speed milling and high speed milling in this experiment, study on effects of different milling parameters (milling depth ap, feed engagement fz, the milling speed vz) on milling force. The results shows that in the same cutting parameters ,the three milling force of ultrasonic longitudinal and torsional vibration high speed milling are smaller than that of high speed milling, and milling forces of two milling method increase with the add of the milling depth and feed engagement ,but they aren't fold increase. Milling forces of two milling method decrease with the add of the the minlling speed,and the changes become gently when the the minlling speed run up to 170m/min, with the further increase of the milling speed,ultrasonic vibration high speed milling will translate to high speed milling, this is because the torsional vibration is submerged.

Milling Force Forecast of the Matching of Lengthened Shrink-Fit Holder and Cutter in High Speed Machining

2010 ◽  
Vol 139-141 ◽  
pp. 827-830
Author(s):  
Hou Ming Zhou ◽  
Jian Xin Deng ◽  
Wen Wei Xie
Keyword(s):  
High Speed ◽  
Back Propagation ◽  
Back Propagation Neural Network ◽  
Force Model ◽  
Milling Force ◽  
Matlab Program ◽  
Force Components ◽  
Shrink Fit ◽  
Milling Forces ◽  
Milling Force Model

Present work of this paper focus on developing a milling force model according to the characteristic of the matching of lengthened shrink-fit holder (LSFH) and cutter using back propagation neural network (BPNN). Time parameter is taken as a factor of the input vector besides 6 processing conditions which mainly affect the milling force, and then the forecasting of 3D transient milling forces are achieved. A lot of milling experiments were performed to get training and testing samples and a Matlab program was designed to evaluate and optimize the network. The test experiments show that the forecasting results are well agreed with the experimental results and the errors of 3D force components are less than 0.18. Besides an extended performance, the BPNN model has higher efficiency and higher accuracy than the customary analytical model.

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

Multi-Toothed Milling Force Model and Simulation for Form Milling the Gear of the Hypoid Gears

2011 ◽  
Vol 328-330 ◽  
pp. 90-95 ◽  
Author(s):  
Xin Jie Jia ◽  
Xiao Zhong Deng ◽  
Xiao Zhong Ren
Keyword(s):  
Face Milling ◽  
Force Model ◽  
Geometrical Theory ◽  
Hypoid Gear ◽  
Milling Force ◽  
Hypoid Gears ◽  
Model And Simulation ◽  
Simulation Results ◽  
Milling Forces ◽  
Milling Force Model

Prediction of the forces in milling hypoid gear was often needed in order to establish automation and optimization of the tooth-milling processes. Based on the geometrical theory of the format face-milling, the multi-toothed milling forces theoretical model for form milling the gear of the hypoid gears is presented, the milling force factors were calibrated via single factor experiments and the simulation programs were prepared. Experiments were carried out to verify the availability of the multi-toothed dynamic milling force model, the experimental results is consistent with the simulation results.

Study on Prediction Model and Experiments of High-Speed Milling Force for Stainless Steel 316

2010 ◽  
Vol 33 ◽  
pp. 6-10
Author(s):  
Wei Feng Zheng ◽  
Jing Quan Wu ◽  
Can Liu ◽  
Guang Hui Li ◽  
Guang Yu Tan
Keyword(s):  
Stainless Steel ◽  
High Speed ◽  
Significant Degree ◽  
Actual Condition ◽  
Linear Regression Method ◽  
Milling Force ◽  
High Speed Milling ◽  
Stainless Steel 316 ◽  
Milling Forces ◽  
Selection Of

Through the orthogonal test in which stainless steel 316 was milled with high speed by solid cemented carbide end cutter, the milling force was measured. By multiple linear regression method, the prediction formula of the milling forces of stainless steel 316 was found. In addition, this study validates to significant degree of the formula meeting the actual condition, which can provide a reference to better selection of cutting parameter in advance and the design of high-speed milling cutter.

scholarly journals Milling Force Model for Aviation Aluminum Alloy: Academic Insight and Perspective Analysis

2021 ◽  
Vol 34 (1) ◽  
Author(s):  
Zhenjing Duan ◽  
Changhe Li ◽  
Wenfeng Ding ◽  
Yanbin Zhang ◽  
Min Yang ◽  
...  
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Cutting Force ◽  
Research Progress ◽  
Machining Accuracy ◽  
Force Model ◽  
Milling Force ◽  
Thin Walled ◽  
Milling Forces ◽  
Milling Force Model

AbstractAluminum alloy is the main structural material of aircraft, launch vehicle, spaceship, and space station and is processed by milling. However, tool wear and vibration are the bottlenecks in the milling process of aviation aluminum alloy. The machining accuracy and surface quality of aluminum alloy milling depend on the cutting parameters, material mechanical properties, machine tools, and other parameters. In particular, milling force is the crucial factor to determine material removal and workpiece surface integrity. However, establishing the prediction model of milling force is important and difficult because milling force is the result of multiparameter coupling of process system. The research progress of cutting force model is reviewed from three modeling methods: empirical model, finite element simulation, and instantaneous milling force model. The problems of cutting force modeling are also determined. In view of these problems, the future work direction is proposed in the following four aspects: (1) high-speed milling is adopted for the thin-walled structure of large aviation with large cutting depth, which easily produces high residual stress. The residual stress should be analyzed under this particular condition. (2) Multiple factors (e.g., eccentric swing milling parameters, lubrication conditions, tools, tool and workpiece deformation, and size effect) should be considered comprehensively when modeling instantaneous milling forces, especially for micro milling and complex surface machining. (3) The database of milling force model, including the corresponding workpiece materials, working condition, cutting tools (geometric figures and coatings), and other parameters, should be established. (4) The effect of chatter on the prediction accuracy of milling force cannot be ignored in thin-walled workpiece milling. (5) The cutting force of aviation aluminum alloy milling under the condition of minimum quantity lubrication (mql) and nanofluid mql should be predicted.

Coupled thermal and mechanical analyses of micro-milling Inconel 718

2018 ◽  
Vol 233 (4) ◽  
pp. 1112-1126 ◽  
Author(s):  
Xiaohong Lu ◽  
Hua Wang ◽  
Zhenyuan Jia ◽  
Yixuan Feng ◽  
Steven Y Liang
Keyword(s):  
Inconel 718 ◽  
Cutting Temperature ◽  
Milling Process ◽  
Micro Milling ◽  
Force Model ◽  
Temperature Model ◽  
Milling Force ◽  
Mechanical Coupling ◽  
Milling Forces ◽  
Milling Force Model

Micro-milling forces, cutting temperature, and thermal–mechanical coupling are the key research topics about the mechanism of micro-milling nickel-based superalloy Inconel 718. Most current analyses of thermal–mechanical coupling in micro-milling are based on finite element or experimental methods. The simulation is not conducive to revealing the micro-milling mechanism, while the results of experiments are only valid for certain machine tool and workpiece material. Few analytical coupling models of cutting force and cutting temperature during micro-milling process have been proposed. Therefore, the authors studied coupled thermal–mechanical analyses of micro-milling Inconel 718 and presented a revised three-dimensional analytical model of micro-milling forces, which considers the effects of the cutting temperature and the ploughing force caused by the arc of cutting edge during shear-dominant cutting process. Then, an analytical cutting temperature model based on Fourier’s law is presented by regarding the contact area as a moving finite-length heat source. Coupling calculation between micro-milling force model and temperature model through an iterative process is conducted. The novelty is including cutting temperature into micro-milling force model, which simulates the interaction between cutting force and cutting temperature during micro-milling process. The established model predicts both micro-milling force and temperature. Finally, experiments are conducted to verify the accuracy of the proposed analytical method. Based on the coupled thermal–mechanical analyses and experimental results, the authors reveal the effects of cutting parameters on micro-milling forces and temperature.

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