Efficient calibration of instantaneous cutting force coefficients and runout parameters for general end mills

Wan, Min; Zhang, W.H.; Qin, Guohua; Tan, Guojin

doi:10.1016/j.ijmachtools.2006.06.012

Cited by 139 publications

(72 citation statements)

References 23 publications

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“…A larger force coefficient at a smaller axial depth of cut was also found by Erdim et al [24]. Several studies [25][26][27] also reported that the cutting force coefficients tend to increase the cut thickness decreases.…”

Section: Comparison Of the Abs With Z-mappingsupporting

confidence: 62%

A hybrid analytical- and discrete-based methodology for determining cutter-workpiece engagement in five-axis milling

Kiswanto

Hendriko

Duc

2015

Int J Adv Manuf Technol

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This paper presents a new method to determine the cutter-workpiece engagement (CWE) for a toroidal cutter during free-form surface machining in five-axis milling. A hybrid method, which is a combination of a discrete model and an analytical approach, was developed. Although the workpiece surface was discretized by a number of normal vectors, there was no calculation to determine the intersection between the normal vector and the cutting tool. The normal vectors were used to define the workpiece surface mathematically; next, the engagement point was calculated using a combination of the workpiece surface equation, the parametric equation of the cutting tool, and the tool orientation data. Three model parts with different surface profiles were tested to verify the validity of the proposed method; the results indicated that the method was accurate. The method also eliminated the need for a large number of discrete vectors to define the workpiece surface. A comparison showed that the proposed method was computationally more efficient. The CWE model was subsequently applied to support the cutting force prediction model. A validation test demonstrated that in terms of trends and amplitudes, the predicted cutting forces exhibit good agreement with the cutting force generated experimentally.

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Section: Comparison Of the Abs With Z-mappingsupporting

confidence: 62%

A hybrid analytical- and discrete-based methodology for determining cutter-workpiece engagement in five-axis milling

Kiswanto

Hendriko

Duc

2015

Int J Adv Manuf Technol

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show abstract

“…(10a) and (10b) need to be calibrated for each cutter-workpiece material pair in order to calculate the ball-end milling forces. Various approaches for calibrating the cutting force coefficients have been proposed in the literature, such as: processing the instantaneous cutting forces rather than the average cutting forces [36], analyzing the experimental force data in the frequency domain [37], separating the cutting forces into nominal and perturbation components [38], using force data generated from a finite element model [39], and considering the negative effect of cutter runout [40].…”

Section: Calibration Approachmentioning

confidence: 99%

Cutting force prediction for ball-end mills with non-horizontal and rotational cutting motions

Azeem

Feng

2012

Int J Adv Manuf Technol

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Accurate cutting force prediction is essential to precision machining operations as cutting force is a process variable that directly relates to machining quality and efficiency. This paper presents an improved mechanistic cutting force model for multi-axis ball-end milling. Multi-axis ballend milling is mainly used for sculptured surface machining where non-horizontal (upward and downward) and rotational cutting tool motions are common. Unlike the existing research studies, the present work attempts to explicitly consider the effect of the 3D cutting motions of the ballend mill on the cutting forces. The main feature of the present work is thus the proposed generalized concept of characterizing the undeformed chip thickness for 3D cutter movements. The proposed concept evaluates the undeformed chip thickness of an engaged cutting element in the principal normal direction of its 3D trochoidal trajectory. This concept is unique and it leads to the first cutting force model that specifically applies to non-horizontal and rotational cutting tool motions. The resulting cutting force model has been validated experimentally with extensive verification test cuts consisting of horizontal, non-horizontal, and rotational cutting motions of a ball-end mill.

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“…In this way, the design accuracy of the whole process, including fixtures, cutting tools and machine tools, can be improved to provide a basis for 1 formulating the cutting parameters and optimising the geometric parameters of the tools used. 1 Common milling force models are empirical, mechanical, finite element (FE) and neural networks based on artificial intelligence and so on. [2][3][4][5] In terms of milling force modelling for stainless steel, through the single factor experiments testing the influence of the factors, including milling depth, line space and feed per tooth, on milling force, three-dimensional (3D) milling force data were obtained by Li et al based on the characteristics of stainless steel materials.…”

Section: Introductionmentioning

confidence: 99%

Experimental tests and empirical models of the cutting force and surface roughness when cutting 1Cr13 martensitic stainless steel with a coated carbide tool

et al. 2016

Advances in Mechanical Engineering

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Cutting force prediction is the key issue for planning and optimising the machining process. To explore the cutting of difficult-to-machine 1Cr13 martensitic stainless steel, an orthogonal test was conducted to study the cutting force and surface roughness under the dry, full-width milling. In addition, an empirical model, applied to the exponential forms of the cutting force and surface roughness of 1Cr13 martensitic stainless steel, was established by data processing and linear regression. It can be seen that the significance levels of the influence of cutting parameters on cutting force, surface roughness were cutting depth a p , feed per tooth f and cutting speed v during APMT 1135 PDTR coated carbide tool milling of 1Cr13 stainless steel at high speed by testing the significance of regression relationships and their coefficients. It was found that the predictive model offered high accuracy. The cutting parameters that affect the cutting force and surface roughness in milling machining were analysed and the common rules were concluded in this article based on a series of cutting experiments. And those rules can be used as the scientific theory evidence for cutting-parameter selection in the milling machining.

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Efficient calibration of instantaneous cutting force coefficients and runout parameters for general end mills

Cited by 139 publications

References 23 publications

A hybrid analytical- and discrete-based methodology for determining cutter-workpiece engagement in five-axis milling

A hybrid analytical- and discrete-based methodology for determining cutter-workpiece engagement in five-axis milling

Cutting force prediction for ball-end mills with non-horizontal and rotational cutting motions

Experimental tests and empirical models of the cutting force and surface roughness when cutting 1Cr13 martensitic stainless steel with a coated carbide tool

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