An analytical force model with shearing and ploughing mechanisms for end milling

Wang, Jiunn-Jyh Junz; Zheng, C. M.

doi:10.1016/s0890-6955(02)00019-6

Cited by 60 publications

(19 citation statements)

References 14 publications

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“…(ii) When the actual uncut chip thickness h a (t, k) is larger than the minimum chip thickness, the interaction forces of the workpiece with the cutter are dominated by shearing forces, and all material as thick as the actual engagement is assumed to be removed as a chip. The tangential cutting force F t , radial cutting force F r and axial cutting force F a are modeled as (Wang et al 2002) dF…”

Section: Three-dimensional Cutting Force Modelmentioning

confidence: 99%

Modeling of three-dimensional cutting forces in micro-end-milling

Li¹,

Lai²,

Li³

et al. 2007

J. Micromech. Microeng.

100

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A new nominal uncut chip thickness algorithm for micro-scale end-milling is proposed by considering the combination of an exact trochoidal trajectory of the tool tip and tool run-out, and then the actual uncut chip thickness may be obtained from a comparison between the current accumulative uncut chip thickness and the minimum chip thickness. Due to the intermittency of the chip formation, the milling process is divided into an elastic-plastic deformation regime and a chip formation regime dominated by ploughing forces and shearing forces, respectively, and three-dimensional cutting forces are modeled according to different regimes. Based on the modeling and simulation technologies introduced, a simulation system for the prediction of three-dimensional cutting forces of a micro-scale end-milling process is developed. The simulation results show a very satisfactory agreement with those data from milling experiments.

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Section: Three-dimensional Cutting Force Modelmentioning

confidence: 99%

Modeling of three-dimensional cutting forces in micro-end-milling

Li¹,

Lai²,

Li³

et al. 2007

J. Micromech. Microeng.

100

View full text Add to dashboard Cite

show abstract

“…The two coefficients, calculated from the average chip thickness of given process parameters, are treated as constants when calculating the local cutting force with respect to the varying chip thickness. The cutting coefficients in the aforementioned model represent the lumped effects of the shearing and ploughing mechanisms, and this was defined as the lumped global cutting constant (LGCC) model by Wang and Zheng [18]. Thus, the lumped cutting coefficients are constants with respect to the varying local chip thickness.…”

Section: Introductionmentioning

confidence: 99%

“…Thus, the lumped cutting coefficients are constants with respect to the varying local chip thickness. In [18], the dual-mechanism counterpart of LGCC was defined as the dual-mechanism global cutting constant (DGCC), where the shearing and ploughing cutting coefficients are separately considered, assumed to be independent of the varying chip thickness and, thus, referred to as cutting constants. Yellowley [19] presented the first DGCC 2D milling force model, which assumed that both the shearing coefficient and the ploughing coefficient are constant.…”

Section: Introductionmentioning

confidence: 99%

“…Zheng et al [21] presented a three-dimensional convolution model for cutting forces in peripheral end milling on the basis of lumped cutting constants, cutting parameters, machining configuration, and tool/work geometry. Wang and Zheng [18] extended the convolution approach to establish a three-axis DGCC force model for end milling. In these time-domain convolution models, Fourier coefficients of the periodic milling forces can be analytically obtained through Fourier transform and expressed in terms of LGCCs or DGCCs.…”

Section: Introductionmentioning

confidence: 99%

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Prediction of Shearing and Ploughing Constants in Milling of Inconel 718

Lin

Lui

Lin

et al. 2021

JMMP

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The present study proposes an integrated prediction model for both shearing and ploughing constants for the peripheral milling of Inconel 718 by using a preidentified mean normal friction coefficient. An equation is presented for the identification of normal mean friction angle of oblique cutting in milling. A simplified oblique cutting model is adopted for obtaining the shear strain and shearing constants for a tool of given helix angle, radial rake angle, and honed edge radius. The shearing and ploughing constants predicted from analytical model using the Merchant’s shear angle formula and the shear flow stress from the selected Johnson–Cook material law are shown to be consistent with the experimental results. The experimentally identified normal friction angles and shearing and edge ploughing constants for the Inconel 718 milling process are demonstrated to have approximately constant values irrespective of the average chip thickness. Moreover, the predicted forces obtained in milling aged Inconel 718 alloy are in good agreement with the experimental force measurements reported in the literature. Without considering the thermal–mechanical coupling effect in the material law, the presented model is demonstrated to work well for milling of both annealed and aged Inconel 718.

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“…Bissacco et al 12 proposed a cutting force model in which a sliding plane for the chip movement is considered based on the relationship between uncut chip thickness and the tool edge radius. Junz Wang and Zheng 13 developed an analytical method for end milling by explicitly considering the shearing and ploughing components of the force.…”

Section: Introductionmentioning

confidence: 99%

Prediction of cutting force in micro-end-milling by a combination of analytical and FEM method

Roushan

Rao

Vijayaraghavan

2020

Journal of Micromanufacturing

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Mechanical micro-machining, in general, and micro-end-milling, in particular, has become a very good technique for fabricating 3D micro-features in a variety of materials. To optimize and control the process, prediction of the cutting force accurately is very important. In this work, a force prediction model is developed by a combination of analytical method and finite element (FE) simulations. The model predicts the cutting force components for micro-end-milling process successfully which is compared with experimental force signal obtained by using Al2024-T3 and AISI 4340 as workpiece materials. The predicted and experimental cutting forces are in very good agreement for both the amplitude and trend of the cutting force. The percentage deviation of the predicted force from the experimental force values for both feed force ( Fx) and transverse force ( Fy) is around 15% (except one case) for Al2024-T3. For the AISI 4340 material, the percentage deviation for Fx is around 25% and for Fy is approximately 10%. The methodology followed here is general in nature and it can be applied to any other machining process as well.

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An analytical force model with shearing and ploughing mechanisms for end milling

Cited by 60 publications

References 14 publications

Modeling of three-dimensional cutting forces in micro-end-milling

Modeling of three-dimensional cutting forces in micro-end-milling

Prediction of Shearing and Ploughing Constants in Milling of Inconel 718

Prediction of cutting force in micro-end-milling by a combination of analytical and FEM method

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