Instantaneous Cutting Force Model in High-Speed Milling Process with Gyroscopic Effect

2011 ◽  
Vol 314-316 ◽  
pp. 389-392
Author(s):  
Hong Liang Zhou ◽  
Wei Xiao Tang ◽  
Qing Hua Song ◽  
Hua Wei Ju
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
End Milling ◽  
Element Model ◽  
Face Milling ◽  
Force Model ◽  
Dynamics Model ◽  
Cutting Force Model ◽  
Gyroscopic Effect ◽  
High Speed Milling

High-speed milling (HSM) has advantages in high productivity high precision and low production cost. Thus it can be widely used in the manufacture industry. However, when the speed of spindle-tool reaches a higher speed range, the gyroscopic effect will become an important part of its stable milling. In this paper, a dynamics model of HSM system was proposed considering the influence of gyroscopic moment due to high rotating speed of end milling. Finite element model (FEM) is used to model the dynamics of a spindle-milling system. It obtains the trajectory of central point in face milling with considering gyroscopic effects through the dynamics model at high speeds. Then the cutting force model will be corrected by the trajectory of face milling. So it can provide a basis for stability prediction of high speed milling.

Stability of High Speed Milling Based on Instantaneous Cutting Force

2012 ◽  
Vol 152-154 ◽  
pp. 404-408
Author(s):  
Hong Liang Zhou ◽  
Wei Xiao Tang ◽  
Qing Hua Song
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
End Milling ◽  
Element Model ◽  
Face Milling ◽  
Force Model ◽  
Dynamics Model ◽  
High Speed Milling ◽  
High Productivity ◽  
Rotating Speed

High-speed milling (HSM) has advantages in high productivity high precision and low production cost. Thus it can be widely used in the manufacture industry. However, when the speed of spindle-tool reaches a higher speed range, the gyroscopic effect will become an important part of its stable milling. In this paper, a dynamics model of HSM system was proposed considering the influence of gyroscopic moment due to high rotating speed of end milling. Finite element model (FEM) is used to model the dynamics of a spindle-milling system. It obtains the trajectory of central point in face milling with considering gyroscopic effects through the dynamics model at high speeds. Then the cutting force model will be corrected by the trajectory of face milling. Then the stability lobes diagrams (SLD) was elaborated. Cutting thickness effects have non-negligible impact on stability limitation.

An Improved Tool Path Model Including Gyroscopic Effect for Instantaneous Cutting Force Prediction in High-Speed Milling

2011 ◽  
Vol 418-420 ◽  
pp. 840-843
Author(s):  
Qing Hua Song ◽  
Xing Ai
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Tool Path ◽  
Milling Process ◽  
Path Model ◽  
Force Model ◽  
Cutting Force Model ◽  
Gyroscopic Effect ◽  
Cutting Force Prediction ◽  
High Speed Milling

The efficiency of the high-speed milling process is often limited by the occurrence of chatter. In order to predict the occurrence of chatter, accurate models are necessary. With the speed increasing, gyroscopic effect plays an important pole on the system behavior, including dynamic characteristic and rotating behavior. Considering the influence of gyroscopic effect on rotating behavior, an updated model for the milling process is presented which features as model of the equivalent profile of tool. In combination with this model, a nonlinear instantaneous cutting force model is proposed. The use of this updated equivalent profile of tool results in significant differences in the static uncut thickness compared to the traditional model.

scholarly journals Analysis of Cutting Forces From Conventional to High-Speed Milling with Straight and Helical-Flute Tools for Flat-End Milling Incorporating the Effect of Tool Runout

2021 ◽  
Author(s):  
Mehmet AYDIN ◽  
Uğur Köklü
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
End Milling ◽  
Spindle Speed ◽  
Force Model ◽  
Workpiece Material ◽  
High Speed Milling ◽  
Tool Runout ◽  
Flat End Milling

Abstract This paper presents a systematic study to analyze the dependence of cutting forces on tool geometry, workpiece material and cutting parameters such as spindle speed, tool engagement and cutting direction in flat-end milling with tool runout. The cutting forces are determined according to a mechanistic force model considering the trochoidal flute path to calculate the undeformed chip thickness, and average cutting force and linear regression model are applied for identifying the coefficients of the force model. A series of milling processes are conducted on AZ31 Magnesium (Mg) alloy and titanium alloy (Ti6Al4V) to analyze the instantaneous cutting force curves, amplitudes of cutting forces and peak forces over a wide range of spindle speeds from conventional to high-speed milling. It is demonstrated that the values of the cutting force coefficients are higher at conventional spindle speed and decrease with an increase in spindle speed, especially when machining Ti6Al4V alloy. For the edge force coefficients, it is observed a slight variation when using cutting tools with different helix angles. Besides, the cutting force amplitudes strongly depend upon the workpiece material. The helix angle has a significant influence on the transverse force amplitude at conventional speed. The forces obtained mechanistically are also substantiated by comparison with measurements.

A Hybrid Cutting Force Model for High-speed Milling of Titanium Alloys

CIRP Annals ◽  
2005 ◽  
Vol 54 (1) ◽  
pp. 71-74 ◽  
Author(s):  
Z.G. Wang ◽  
M. Rahman ◽  
Y.S. Wong ◽  
X.P. Li
Keyword(s):  
Titanium Alloys ◽  
Cutting Force ◽  
High Speed ◽  
Force Model ◽  
Cutting Force Model ◽  
High Speed Milling

Research on Multi-Axis High Speed Machining Milling Force of Aeroengine Impeller

2010 ◽  
Vol 455 ◽  
pp. 87-91
Author(s):  
Y.Y. Guo ◽  
Can Zhao ◽  
Wei Gang Du
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
End Milling ◽  
Model Simulation ◽  
Differential Method ◽  
Force Model ◽  
High Speed Machining ◽  
Cutting Force Model ◽  
Ball End Milling ◽  
The Relationship

On the basis of the ball-end milling feature during high-speed machining impeller, the relationship between cutting force and chips is analyzed in this paper. The model of ball-end milling cutter cutting force is founded through differential method. And the coefficients solution of cutting force model is expounded. Besides, the coefficients solution and the cutting force model simulation are implemented by the software Matlab.

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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