Effect of direction of parameterization on cutting forces and surface error in machining curved geometries

Desai, K. A.; Rao, P. Venkateswara

doi:10.1016/j.ijmachtools.2007.08.007

Cited by 28 publications

(7 citation statements)

References 21 publications

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“…The accuracy of the model is verified by cutting experiments on aluminum alloy Al6061. Desai et al [159] studied the influence of parametric machining direction and tool diameter on the machining geometry, cutting force, and surface error in cylindrical milling of curved surface geometry. The experimental results of 7075-T6 aluminum alloy are consistent with those of computer simulation.…”

Section: Micro Element Milling Force Modelmentioning

confidence: 99%

Milling Force Model for Aviation Aluminum Alloy: Academic Insight and Perspective Analysis

Duan

Ding

et al. 2021

Chin. J. Mech. Eng.

176

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Aluminum 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.

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Section: Micro Element Milling Force Modelmentioning

confidence: 99%

Milling Force Model for Aviation Aluminum Alloy: Academic Insight and Perspective Analysis

Duan

Ding

et al. 2021

Chin. J. Mech. Eng.

176

View full text Add to dashboard Cite

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“…Desai and Rao determined the effect of variable curvature geometries by machining from both parametric directions and using cutters of different diameters. They determined that a considerable amount of shift in the location of peak cutting forces with the change in cutting direction and cutter diameter, particularly in concave regions of the workpiece geometry [8]. Alberti et al [24].…”

Section: The Effects Of Milling Strategies On Forces Materials Removamentioning

confidence: 99%

The Effects of Milling Strategies on Forces, Material Removal Rate, Tool Deflection, and Surface Errors for the Rough Machining of Complex Surfaces

Bagci

Yuncuoglu

2017

SV-JME

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Sculptured/curved surfaces, today, are widely used in several industries, for instance, automotive, aerospace, bio-medical components, precision machine design and die-mould industries. Recent improvements in CAM software have allowed the manufacturing of complex curved geometries. The ball-end/nose milling is a flexible process that is capable of milling both convex and concave part surfaces with rough, semi-rough and finish processes. The sculptured surface milling is mostly realized by the repeated motion of a rotating cutter along predefined trajectories. Manufacturing engineers can choose the cutter paths generation approach from a set of typical paths (zig, zig-zag, concentric, radial tool paths, etc.) in commercial CAM software. In addition, these strategies cannot be optimized for all complex surfaces to be milled. A substantial number of studies have examined this subject, and many path-generation approaches have been developed, as shown in Fig. 1 [1] and [2].The strategies can be sorted into three basic categories: offset, single direction, and raster. In offset milling, the cutter starts at the periphery of the face and then proceeds spirally inwards. In a raster milling strategy (zig, zig-zag, or sweep) the cutting tool moves back and forth across the milled workpiece [3]. In spiral milling, the cutter returns to the start-point of each cycle and then cuts outwards to the next outer cycle. When using a spiral strategy, the cutting time is hugely decreased. The selection of the proper milling strategy in the process of milling will decrease cutting time, improve the surface quality of the finished part and tool life and reduce machining costs and cutting forces. Kurt

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“…The cutting force modelling along a circular tool path would require a modified feed per tooth calculation based on the distance between two consecutive epitrochoidal tooth trajectories. There has been a report of changes in cutting force profiles due to variation in the curvature of tool path geometry [33]. This was dealt with by representing the circular tool path as consisting of discretized linear intervals and using modified cutting parameters [34].…”

Section: Machining Parameter Selectionmentioning

confidence: 99%

Process planning for corner machining based on a looping tool path strategy

Banerjee

Feng

Bordatchev

2011

Proceedings of the Institution of Mechanical Engineers, Part B:

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Access and use of this website and the material on it are subject to the Terms and Conditions set forth at Process planning for corner machining based on a looping tool path strategy Banerjee, A.; Feng, H.-Y.; Bordatchev, E.V. NRC Publications Record / Notice d'Archives des publications de CNRC:http://nparc.cisti-icist.nrc-cnrc.gc.ca/npsi/ctrl?action=rtdoc&an=21271270&lang=en http://nparc.cisti-icist.nrc-cnrc.gc.ca/npsi/ctrl?action=rtdoc&an=21271270&lang=fr READ THESE TERMS AND CONDITIONS CAREFULLY BEFORE USING THIS WEBSITE.http://nparc.cisti-icist.nrc-cnrc.gc.ca/npsi/jsp/nparc_cp.jsp?lang=en Vous avez des questions? Nous pouvons vous aider. Pour communiquer directement avec un auteur, consultez la première page de la revue dans laquelle son article a été publié afin de trouver ses coordonnées. Si vous n'arrivez pas à les repérer, communiquez avec nous à PublicationsArchive-ArchivesPublications@nrc-cnrc.gc.ca.

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Effect of direction of parameterization on cutting forces and surface error in machining curved geometries

Cited by 28 publications

References 21 publications

Milling Force Model for Aviation Aluminum Alloy: Academic Insight and Perspective Analysis

Milling Force Model for Aviation Aluminum Alloy: Academic Insight and Perspective Analysis

The Effects of Milling Strategies on Forces, Material Removal Rate, Tool Deflection, and Surface Errors for the Rough Machining of Complex Surfaces

Process planning for corner machining based on a looping tool path strategy

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