A Model for Energy Consumption of Main Cutting Force of High Energy Efficiency Milling Cutter under Vibration

Abstract

Understanding the influence of the main cutting force energy consumption of the milling cutter is the basis for prediction and control of energy and machining efficiency. The existing models of cutting force energy consumption lack variables related to milling vibration and cutter teeth errors. According to the instantaneous bias of the main profile of the milling cutter under vibration, the instantaneous cutting boundary of the cutter teeth was investigated. The energy consumption distribution of the instantaneous main cutting force of the cutter tooth was studied. The model for the energy consumption of the instantaneous main cutting force of the cutter tooth and the milling cutter were both developed. The formation of energy consumption of the dynamic main cutting force of a high energy efficiency milling cutter was researched. A method for identifying the time–frequency characteristics of the energy consumption of the main cutting force under vibration was proposed and verified by experiments.

Cutting Energy Consumption Modelling of End Milling Cutter Coated with AlTiCrN

“…( ) Energy consumption is the integration of power in time. The model of cutting energy consumption can be calculated as Equation (15).…”

“…the tool wear in the model of Shi et al [14] are quadratic function. Jiang et al [15] establish an instantaneous energy consumption model considering milling vibration and tool tooth error based on milling force. The energy consumption models are established by the cutting force in the above literature.…”

Digital twin of the technological process for grinding helical flutes of a cutting tool

“…End mills have found wide application in mechanical engineering, aerospace, and the production of agricultural machinery [21,22]. The designs of end mills have a wide variety: when milling parts with thin walls with low rigidity, uneven force deformation occurs, obvious problems with vibrations; cutters are used to reduce vibrations with variable cutting edge pitch [23]; Ceramic end mills are used for processing heat-resistant materials [24]; In addition, there are many standard traditional end designs with helical flutes with profiles of various shapes as shown in [25]; high-performance processing of steels and cast irons is carried out using end mills with a double toroidal cutting surface [26,27]; For finishing machining with greater stability, multi-flute cutters with a shallow profile and a long transverse cutting tooth are used [28].…”