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.

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.

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.

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.

Modeling of dynamic milling forces considering the interlaminar effect during milling multidirectional CFRP laminate

2020 ◽  
pp. 073168442097176
Author(s):  
Fuji Wang ◽  
Guangjian Bi ◽  
Fuda Ning
Keyword(s):  
Superposition Principle ◽  
Milling Process ◽  
Force Model ◽  
Milling Force ◽  
Cfrp Laminate ◽  
Near Net Shape ◽  
Milling Forces ◽  
Milling Force Model ◽  
First Time

The milling process is always required to achieve dimensional tolerance for the near-net-shape carbon fiber reinforced polymer (CFRP) parts. However, delamination and cracking are inevitably induced in milling CFRP due to the excessive milling forces. The milling forces should be thereby well controlled to reduce damages of CFRP parts. Developing a theoretical milling force model is an effective approach to understand the mechanism of milling force generation. Recent studies have established the predictive models; however, the interlaminar effect impacting the material removal process is not considered during milling multidirectional CFRP laminate, limiting the predictive model accuracy. In this work, a model of dynamic milling force for multidirectional CFRP laminate was developed by considering the interlaminar effect for the first time. The specific cutting energy predicted by the artificial neural network methodology was employed to calculate the milling forces during milling a single CFRP layer. Meantime, the support of the layer was enhanced due to the interlaminar effect, and the correction coefficients for each type of support were proposed to reflect the role of this effect. Then, the overall milling forces for multidirectional CFRP laminate can be obtained via the superposition principle, which agreed well with the experimentally measured results.

Simulation and Optimal Selection of Pitch Angles Distribution for Variable Pitch Angles Helix End Mills

2010 ◽  
Vol 443 ◽  
pp. 285-290
Author(s):  
Pan Ling Huang ◽  
Jian Feng Li ◽  
Jie Sun
Keyword(s):  
Cutting Parameters ◽  
Force Model ◽  
Optimal Selection ◽  
Milling Force ◽  
Frequency Spectra ◽  
Variable Pitch ◽  
End Mills ◽  
Milling Forces ◽  
Milling Force Model ◽  
Selection Of

In the paper, a static milling force model for variable pitch mills was built, and the milling forces were simulated. The resultant force and its frequency spectra of variable pitch mills were analyzed compared with that of uniform pitch mills. It is shown that the standard deviation (SD) of frequency spectra amplitudes for variable pitch mills is extremely lower than that of uniform pitch mills. Through simulation for SD of frequency spectra amplitudes affected by the different cutting parameters, a pitch angles distribution of variable pitch helix end mills with lower SD of frequency spectra amplitudes was selected.

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.

scholarly journals A novel milling force model based on the influence of tool geometric parameters in end milling

2018 ◽  
Vol 10 (9) ◽  
pp. 168781401879818 ◽  
Author(s):  
Xianglei Zhang ◽  
Jing Zhang ◽  
Hongming Zhou ◽  
Yan Ren ◽  
Mingming Xu
Keyword(s):  
End Milling ◽  
Geometric Parameters ◽  
Force Model ◽  
The Novel ◽  
Milling Force ◽  
Prediction Ability ◽  
Loop Method ◽  
Milling Forces ◽  
Milling Force Model ◽  
Novel Model

A novel milling force model for cutting aviation aluminum alloy 7075 using carbide end mill is established in this article. A two-dimensional end-milling model is set up to investigate the influence of tool geometric parameters on milling force with the single-factor analysis. The relationship between milling forces and tool geometric parameters is obtained by nonlinear regression fitting method. Based on the existing empirical model of milling force, quadratic polynomial factor is taken into consideration to explore the influence of tool geometric parameters on milling force. Thus, a novel milling force model is built up which includes tool geometric parameters and milling parameters. The coefficients of the novel model are identified by the direct method and the loop method. The precisions of the coefficients obtained by the two methods are compared between prediction values and experiment values. After comparison, the model whose coefficients are obtained by loop method has higher prediction ability. End-milling experiments were carried out to verify the prediction accuracy of the novel milling force model. The result shows that the novel model of milling force has high accuracy in prediction. The method of building the milling force model proposed in this article can be applied to other types of milling cutter.

A Cutting Force Model for Face Milling Operation

2013 ◽  
Vol 765-767 ◽  
pp. 378-381 ◽  
Author(s):  
Dong Hong Tang ◽  
Fang Lu
Keyword(s):  
Design Theory ◽  
Orthogonal Design ◽  
Face Milling ◽  
Partial Least Square ◽  
Least Square ◽  
Partial Least Square Regression ◽  
Force Model ◽  
Dynamic Force ◽  
Milling Force ◽  
Milling Force Model

Based on the geometry of the cutter, the dynamic force model of face milling was established. Meanwhile, the fast and effective identification method of milling force model coefficients was provided, which combining the virtues of both orthogonal design theory and partial least-square regression (PLSR) method. Milling experiments have been conducted to verify the proposed face milling force model. Good agreements between the experimental and simulated results were presented.

Modeling and Simulation of Milling Forces for Ball-End Cutter with Considering Comprehensive Factors

2011 ◽  
Vol 121-126 ◽  
pp. 2098-2104
Author(s):  
Xiu Lin Sui ◽  
Ping Zhang
Keyword(s):  
Chip Thickness ◽  
Milling Process ◽  
Differential Method ◽  
Physical Factors ◽  
Force Model ◽  
Milling Force ◽  
Cutter Deflection ◽  
Set Up ◽  
Milling Forces ◽  
Milling Force Model

In this paper, influence mechanism of variously physical factors for milling force in any feed direction is studied during the milling process. Firstly, the effects of spindle eccentricity, cutter deflection and cutter vibration for the instantaneously undeformed cutting thickness are analyzed, and the mathematical expressions of chip thickness is set up. Then,on this basis of cutting force and chip load, the milling force model of ball-end mill with considering integrated physical factors is established though the differential method, and a simulation system for prediction of milling forces during the milling process is developed. This milling force model is verified through simulation and analysis of milling forces.

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