Cutting Force and Finish Surface Simulation of End Milling Operation in Consideration of Static Tool Deflection by Using Voxel Model

Nishida, Isamu; Okumura, Ryuma; Sato, Ryuta; Shirase, Keiichi

doi:10.1016/j.procir.2018.08.218

Cited by 14 publications

(6 citation statements)

References 3 publications

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“…Therefore, the adoption of a cutting model is essential to predict α enc . In this analysis, a simple mechanistic cutting model (8,9,10) analogous to the one used in other works [25][26][27], is considered.…”

Section: Single Fluted Endmill Force Shape Classificationmentioning

confidence: 99%

“…(8) (9) (10) where h is the chip thickness, fz is the feed per tooth, K tc and K rc are respectively the tangential and the radial cutting coefficients while b is the chip width.…”

Section: Single Fluted Endmill Force Shape Classificationmentioning

confidence: 99%

“…vibrations [7][8][9]) and static aspects (e.g. tool deflection [10,11]). Dynamic mechanisms impact on the machined surface mostly at the roughness level [12], instead static mechanisms affect the ma-chined surface mainly at the form level [13].…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Extended classification of surface errors shapes in peripheral end-milling operations

Morelli

Grossi

Scippa

et al. 2021

Journal of Manufacturing Processes

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Section: Single Fluted Endmill Force Shape Classificationmentioning

confidence: 99%

“…(8) (9) (10) where h is the chip thickness, fz is the feed per tooth, K tc and K rc are respectively the tangential and the radial cutting coefficients while b is the chip width.…”

Section: Single Fluted Endmill Force Shape Classificationmentioning

confidence: 99%

See 1 more Smart Citation

Extended classification of surface errors shapes in peripheral end-milling operations

Morelli

Grossi

Scippa

et al. 2021

Journal of Manufacturing Processes

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“…Nishida et al [10] proposed a method for calculating the removed voxels in discrete intervals of the tool's rotation angle, as shown in Figure 2a. The tool is divided into disks perpendicular to the tool axis, and the removal of voxels is done by detecting those that lie in each disk, as shown in Figure 2b.…”

Section: Introductionmentioning

confidence: 99%

Application of Geometric Simulation for Determination of Dynamic Undeformed Chip Thickness in Milling

Bombiński¹,

Jemielniak²

2023

Adv. Sci. Technol. Res. J.

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Self-excited vibration is a significant constraint on productivity and production quality, which makes various forms of virtual machining widely used to find stable conditions before starting the actual machining operation. Numerical simulation of self-excited vibration, although much slower than analytical solutions, makes it possible to consider the nonlinearity of the process and its continuous variation. In 5-axis milling, predicting the instantaneous cross-sections of the uncut chip is very difficult, so geometric simulation is readily used to check the correctness of the NC program and the obtained shape of the workpiece. However, the known solutions take into consideration only programmed movements of the tool relative to the workpiece without considering vibrations, and those in which attempts have been made to consider vibrations have significant limitations. This paper uses a Geometric Simulator that determines the nominal positions of the tool relative to the workpiece, to which the displacements due to vibration, determined by the Dynamic Simulator, are added, making it possible to effectively determine the dynamic thickness of the cut layer and the trace on the workpiece material left by the vibrating tool. The use of geometric simulation, in which the material is represented by discrete voxels, introduces signal quantization, that is, the limited resolution of undeformed chip thickness and trace left on the machined surface. The paper presents the effect of voxel dimension on the accuracy of the simulation of self-excited vibrations

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“…In machining, the analysis of cutting forces is essential to increase both quality and productivity of the process [Liu 2002]. Indeed, the prediction of cutting forces is crucial to handle both static phenomena (i.e., static deflection [Nishida 2018;Grossi 2019]) and dynamic issues (i.e., vibrations [Budak 2003;Grossi 2017]). For 3-axis milling, many studies have been proposed concerning the prediction of cutting forces [Kapoor 1997;Matsumura 2017;Kiran 2019;Ducroux 2021].…”

Section: Introductionmentioning

confidence: 99%

Depths of Cut Identification in 3-Axis Milling Using Cutting Force Spectrum

Morelli¹,

Grossi²,

Scippa³

et al. 2021

MM SJ

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Cutting forces analysis is one of the most important means of improving machining quality and productivity. In 3-axis milling, the frequency domain analysis of the cutting forces provides information which can be adopted for both predicting and monitoring the cutting process. However, the evaluation of the cutting forces spectra requires the application of specific tools (i.e., Fourier’s Transform) to the time domain representation of the same cutting forces. This paper presents analytical formulations to directly evaluate the cutting force spectra starting from the tool geometry and the cutting parameters. The proposed formulations start from the expression of the cutting forces as a Fourier series and enhance the predictions showed in previous works by reducing the overall number of calculations needed. Then, the proposed formulations are applied to identify both radial and axial depths of cut exploiting the normalized cutting force spectrum. Finally, the proposed formulations and their application were numerically and experimentally validated. This work represents a preliminary step in the development of a monitoring system to identify cutting conditions in 3-axis milling.

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Cutting Force and Finish Surface Simulation of End Milling Operation in Consideration of Static Tool Deflection by Using Voxel Model

Cited by 14 publications

References 3 publications

Extended classification of surface errors shapes in peripheral end-milling operations

Extended classification of surface errors shapes in peripheral end-milling operations

Application of Geometric Simulation for Determination of Dynamic Undeformed Chip Thickness in Milling

Depths of Cut Identification in 3-Axis Milling Using Cutting Force Spectrum

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