Cutting edge element modeling-based cutter-workpiece engagement determination and cutting force prediction in five-axis milling

Duan, Xianyin; Peng, Fangyu; Zhu, Zhi‐Biao; Jiang, Guozhang

doi:10.1007/s00170-018-3082-7

Cited by 15 publications

(8 citation statements)

References 13 publications

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“…When using the vector projection method to calculate IUCT, some studies have analyzed the translation and rotation of cutting edge elements [8,10], while in other studies, the detailed analysis of the cutter spatial motion is rarely carried out. The purpose of this section is to accurately represent the cutter spatial motion in the form of screw.…”

Section: Screw Modeling Based On the Cutter Spatial Motion Decompositionmentioning

confidence: 99%

“…Hence, the influence of the tool path curvature and torsion, and cutterorientation change on CWE can be regarded as the result of their influence on IUCT. For this reason, this paper does not directly establish the CWE model, but determines the cutting state of the cutting edge elements based on their IUCT and position relative to the workpiece surface, which is similar to the method in references [7,10,12]. And the difference is that the IUCT model in this paper takes into account the tool path curvature and torsion, and cutter-orientation change, so the accuracy of judging the cutting state of the cutting edge elements is improved compared with references [7,10,12].…”

Section: Cutting State Judgment Of Cutting Edge Elementsmentioning

confidence: 99%

“…Wojciechowski and Mrozek [15] established an IUCT model considering run out, minimum IUCT, and kinematics of low radial immersion milling with tool axis inclination, and further considering the chip thickness accumulation for higher cutting force simulation accuracy [16]. Although some of the previous studies have analyzed the translation and rotation of cutting edge elements [8,10], none of them can reveal the essential reasons affecting the IUCT, which is analyzed in this paper by the screw model. In this paper, the method of calculating IUCT is developed with the vector projection method based on the screw, which can fully consider the influence of the tool path curvature and torsion, and cutter-orientation change on the cutter spatial motion, thereby improving the calculation accuracy of the IUCT in the corresponding machining conditions.…”

Section: Introductionmentioning

confidence: 99%

“…Wang et al [9] calculated the feed vectors of cutting edge elements according to the two adjacent tool positions. Duan et al [10] accurately analyzed the translation and rotation of the cutting edge elements. All the above works were to obtain the feed vector more accurately for higher precision of IUCT.…”

Section: Introductionmentioning

confidence: 99%

“…Kiswanto et al [22] calculated the lower engagement point and the upper engagement point to obtain CWE for the step workpiece surface left by semi-finishing. The third are the discrete modeling methods, which obtain CWE by discretizing the cutter surface and workpiece surface, such as z-buffer [8], Octree [23], dexel [24], and the most commonly used z-map [3,7,10,12,25]. Cao et al [26] and Yuan et al [27] calculated CWE considering the surface curvature and cutter orientations.…”

Section: Introductionmentioning

confidence: 99%

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Cutting force prediction considering tool path curvature and torsion based on screw theory

Zhu

Yan

et al. 2021

Int J Adv Manuf Technol

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There are common features such as the tool path curvature and torsion, and cutter-orientation change in sculptured surface machining, which bring new challenges to the accurate prediction of cutting force. Aiming at the tool path curvature and torsion, and cutter-orientation change, a cutting force prediction method based on the screw theory is proposed in this paper. For the first time, the screw theory is used to describe the cutter spatial motion, which includes the feed motion considering the tool path curvature and torsion, and cutter-orientation change. Combining with Frenet frame, the analytical formula of the screw of cutting edge elements is derived through the homogeneous coordinate transformation. Then, the instantaneous uncut chip thickness (IUCT) of each cutting edge element is calculated by the vector projection method. And the cutting state of the cutting edge element is determined by its IUCT and position relative to the workpiece surface, which is updated by the cutter envelope surface along the machined tool path derived with the screw. To verify the effectiveness of the proposed cutting force prediction method, a milling experiment is conducted on a conical surface workpiece along a tool path with curvature and torsion characteristics, and changing cutter-orientations. Then, the effects of the tool path curvature and torsion, and cutter-orientation change on the cutting force are simulated and analyzed. The results show that the proposed cutting force model based on the screw theory has higher prediction accuracy for the sculpture surface machining with curving and torsional tool paths and changing cutter-orientations.

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Section: Screw Modeling Based On the Cutter Spatial Motion Decompositionmentioning

confidence: 99%