Statistical Approach for the Development of Tangential Cutting Force Model in End Milling of Ti6Al4V

2011 ◽  
Vol 264-265 ◽  
pp. 1160-1165
Author(s):  
Anayet Ullah Patwari ◽  
A.K.M. Nurul Amin ◽  
Waleed Fekry Faris
Keyword(s):  
Mathematical Model ◽  
Cutting Force ◽  
End Milling ◽  
Dynamic Change ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Accuracy ◽  
Force Model ◽  
Machining Parameters ◽  
Cutting Force Model

Dynamic change in cutting force is one of the major causes of chatter formation in metal cutting which affect machining accuracy. Thus, accurate modeling of cutting force is necessary for the prediction of machining performance and determination of the mechanisms and machining parameters that affect the stability of machining operations. The present paper discusses the development of a mathematical model for predicting the tangential cutting force produced in endmilling operation of Ti6Al4V. The mathematical model for cutting force prediction has been developed in terms of the input cutting parameters cutting speed, feed rate, and axial depth of cut using response surface methodology (RSM). Effects of all the individual cutting parameters on cutting force as well as their interactions are investigated in this study. Central composite design was employed in developing the cutting force model in relation to the primary cutting parameters. The experimental results indicate that the proposed mathematical models suggested could adequately describe the performance indicators within the limits of the factors that are being investigated.

A New Cutting Force Model for Micro-Milling and Determination of Optimal Cutting Parameters

2009 ◽  
Vol 83-86 ◽  
pp. 680-687 ◽  
Author(s):  
Shih Ming Wang ◽  
Zou Sung Chiang ◽  
Da Fun Chen ◽  
Yao Yang Tsai
Keyword(s):  
Cutting Force ◽  
Cutting Parameters ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Machining Accuracy ◽  
Force Model ◽  
Cutting Force Model ◽  
Cutter Deflection ◽  
Proposed Model ◽  
Optimal Cutting Parameters

A new cutting force model of micro-milling was developed based on calculating the instantaneously projected area of cutting in this study. According to the rotation trajectory of cutting edge, the instantaneous cutting area projected to xy-plane was first divided into several portions and determined with rectangular integral. After the cutting coefficients were experimentally investigated, the cutting force of micro-milling with different cutting conditions can be determined. Because the developed cutting force was function of cutting parameters, such as spindle speed, feed rate, depth of cut, with taking the cutter deflection into account it was further used to the determine of optimal cutting parameters for obtaining better cutting efficiency and machining accuracy. To verify the proposed cutting force model and the way to determine the optimal cutting parameters, micro-milling experiments were conducted. The results have shown the feasibility of the proposed model and method.

Cutting Force Model of Aluminum Alloy 2014 in Turning with ANOVA Analysis

2010 ◽  
Vol 42 ◽  
pp. 242-245
Author(s):  
Yong Jie Ma ◽  
Yi Du Zhang ◽  
Xiao Ci Zhao
Keyword(s):  
Aluminum Alloy ◽  
Cutting Force ◽  
Response Surface ◽  
Cutting Forces ◽  
Cutting Parameters ◽  
Quadratic Model ◽  
Surface Model ◽  
Force Model ◽  
Machining Parameters ◽  
Cutting Force Model

In the present study, aluminum alloy 2014 was selected as workpiece material, cutting forces were measured under turning conditions. Cutting parameters, the depth of cut, feed rate, the cutting speed, were considered to arrange the test research. Mathematical model of turning force was solved through response surface methodology (RSM). The fitting of response surface model for the data was studied by analysis of variance (ANOVA). The quadratic model of RSM associated with response optimization technique and composite desirability was used to find optimum values of machining parameters with respect to cutting force values. The turning force coefficients in the model were calibrated with the test results, and the suggested models of cutting forces adequately map within the limits of the cutting parameters considered. Experimental results suggested that the most cutting force among three cutting forces was main cutting force. Main influencing factor on cutting forces was obtained through cutting force models and correlation analysis. Cutting force has a significant influence on the part quality. Based on the cutting force model, a few case studies could be presented to investigate the precision machining of aluminum alloy 2014 thin walled parts.

A 3-D Closed-Form Cutting Force Model for End Milling With Application to Sculptured Surface Milling

1999 ◽  
Author(s):  
T. S. Lee ◽  
R. Farahati ◽  
Y. J. Lin
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Free Form ◽  
Depth Of Cut ◽  
Force Model ◽  
Sculptured Surface ◽  
Cutting Force Model ◽  
Estimation Scheme ◽  
Simulation Results ◽  
Axial Depth

Abstract A comprehensive, 3D mathematical model of desired/optimal cutting force for end milling of free-form surfaces is proposed in this paper. The closed-form predictive model is developed based on a perceptive cutting approach resulting in a cutting force model having a comprehensive set of essential cutting parameters. In particular, the normal rake angle usually missing in most existing models of the same sort is included in the developed model. The model also enables quantitative analyses of the effect of any parameters on the cutting performance of the tool, providing a guideline to improving the tool performance. Since the axial depth of cut varies with time when milling sculptured surface parts, an innovative axial depth of cut estimation scheme is proposed for the generation of 3-D cutting forces. This estimation scheme improves the practicality of most existing predictive cutting force model for milling in which the major attention has been focused on planar milling surface generation. In addition, the proposed model takes the rake surface on the flute of mills as an osculating plane to yield 3-D cutting force expressions with only two steps. This approach greatly reduces the time-consuming mathematical work normally required for obtaining the cutting force expressions. A series of milling simulations for machining free-form parts under scenario cutting conditions have been performed to verify the effectiveness of the proposed cutting force model. The simulation results demonstrate accurate estimating capability of the proposed method for the axial depth of cut estimation. The cutting force responses from the simulation exhibit the same trends as what can be obtained using the empirical mechanic’s model referenced in the literature. Finally, through the simulation results it is also learned that designing a tool with a combination of different helix angles having cutting force signatures similar to that of the single helix angle counterparts is particularly advantageous.

Determination of Cutting Forces for Micro Milling

2008 ◽  
Author(s):  
Shih-Ming Wang ◽  
Zou-Sung Chiang ◽  
Da-Fun Chen
Keyword(s):  
Cutting Force ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Micro Milling ◽  
Force Model ◽  
Machining Parameters ◽  
Cutting Force Model ◽  
Optimal Cutting Parameters

To enhance the implementation of micro milling, it is necessary to clearly understand the dynamic characteristics of micro milling so that proper machining parameters can be used to meet the requirements of application. By taking the effect of minimum chip thickness and rake angle into account, a new cutting force model of micro-milling which is function the instantaneous cutting area and machining coefficients was developed. According to the instantaneous rotation trajectory of cutting edge, the cutting area projected to xy-plane was determined by rectangular integral method, and used to solve the instantaneous cutting area. After the machining coefficients were solved, the cutting force of micro-milling for different radial depths of cut and different axial depths of cut can be predicted. The results of micro-milling experimental have shown that the force model can predict the cutting force accurately by which the optimal cutting parameters can be selected for micro-milling application.

Development of Cutting Force Model of Aluminum Nitride Ceramic Processed by Micro End Milling

2011 ◽  
Vol 87 ◽  
pp. 223-229 ◽  
Author(s):  
Moola Mohan Reddy ◽  
Alexander Gorin ◽  
Khaled A. Abou-El-Hossein
Keyword(s):  
Aluminum Nitride ◽  
Cutting Force ◽  
End Milling ◽  
Depth Of Cut ◽  
Force Model ◽  
Machining Parameters ◽  
Cutting Force Prediction ◽  
Force Equation ◽  
Micro End Milling ◽  
End Mills

Advanced ceramics are difficult to do machining due to brittle nature. High cutting forces will generate in the machining, which will affect the surface integrity of final product. Selection of proper machining parameters is important to obtain less cutting force. The present work deals with the study and development of a cutting force prediction model in end milling operation of Aluminum Nitride ceramic. The cutting force equation developed using Response Surface Methodology (RSM) to analyze the effect of Spindle speed, feed rate and axial depth of cut. The cutting tests were carried under dry condition using two flute square end micro grain carbide end mills.

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.

Simulation of Finite Element Analysis for Cutting Force of High-Speed Dry Gear Milling by Flying Cutter

2011 ◽  
Vol 86 ◽  
pp. 100-103
Author(s):  
Qian Guo ◽  
Chao Lin ◽  
Wei Quan
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Comparative Analysis ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Parameters ◽  
Force Model ◽  
Cutting Force Model ◽  
Element Analysis ◽  
Gear Hobbing

This paper makes the emulate experimental research of cutting force in high-speed dry gear milling by flying cutter with finite element analysis method by using the established cutting force model yet, makes the comparative analysis for the result of simulation experiment and theoretical calculation, verifies the correctness of cutting force model and calculation method, makes the comparative analysis for the influencing relations and changing laws of cutting force and cutting parameters and so many factors, and reveals the cutting mechanism of high-speed dry gear milling by flying cutter initially. By the research of this paper, it provides basic theory for subsequent cutting machine technology of high-speed dry gear hobbing, and establishes the theoretical basis for the spread and exploitation of this technology.

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