Improved dynamic cutting force model in peripheral milling. Part II: experimental verification and prediction

Liu, X.-W.; Cheng, Kai; Webb, Dave; Longstaff, Andrew P.; Widiyarto, Muhammad Helmi Nur

doi:10.1007/s00170-003-1797-5

Cited by 28 publications

(16 citation statements)

References 11 publications

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“…Based on the cutting force model proposed by the authors [22,23], for down milling the total cutting force applied on the ith tooth of the cutter is given by:…”

Section: Dynamic Cutting Force Modelmentioning

confidence: 99%

“…The number of components of this vector depends on the number of clamps C used in the fixture and thus F c 2 R c . The task here is to search in a C-dimensional hyperbox for F c with minimum length that satisfies the stability conditions given by equation (23). This clamping optimization task is then formulated as a bi-level nonlinear programming problem as follows:…”

Section: Nonlinear Optimization Modelmentioning

confidence: 99%

“…The instantaneous machining forces, shown in Figure 7 (during two tool revolutions), are obtained from a milling force model presented in this paper (derived from [22,23]). Note that the effect of the helix angle on the cutting forces is neglected in the force model, resulting in a zero force in the Z direction.…”

Section: Simulation Examplementioning

confidence: 99%

See 2 more Smart Citations

Mathematical methodology for optimization of the clamping forces accounting for workpiece vibratory behaviour

Chaari

Abennadher

Louati

et al. 2014

Int. J. Simul. Multidisci. Des. Optim.

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-This paper addresses the problem of determining the minimum clamping forces that ensure the dynamic fixturing stability. The clamping force optimization problem is formulated as a bi-level nonlinear programming problem and solved using a computational intelligence technique called particle swarm optimization (PSO). Indeed, we present an innovative simulation methodology that is able to study the effects of fixture-workpiece system dynamics and the continuously change due to material removal on fixturing stability and the minimum required clamping forces during machining. The dynamic behaviour of the fixtured workpiece subjected to time-and space-varying machining loads is simulated using a forced vibration model based on the regenerative vibrations of the cutter and workpiece excited by the dynamic cutting forces. Indeed, Material removal significantly affects the fixture-workpiece system dynamics and subsequently the minimum clamping forces required for achieving fixturing dynamic stability.

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“…Based on the cutting force model proposed by the authors [22,23], for down milling the total cutting force applied on the ith tooth of the cutter is given by:…”

Section: Dynamic Cutting Force Modelmentioning

confidence: 99%

Section: Nonlinear Optimization Modelmentioning

confidence: 99%

See 1 more Smart Citation

Mathematical methodology for optimization of the clamping forces accounting for workpiece vibratory behaviour

Chaari

Abennadher

Louati

et al. 2014

Int. J. Simul. Multidisci. Des. Optim.

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show abstract

“…dF ti , dF ri , dF ai are the tangential force, radial force, and axial force, respectively, acting on a differential flute element. According to literature [9,10], the resolution of the differential cutting forces (dF ti , dF ri , and dF ai ) in the X, Y, and Z directions is as follows:…”

Section: Realization Based On Mechatronicsmentioning

confidence: 99%

The milling–milling machining method and its realization

Shen-wang

Wang

Xie

et al. 2014

Int J Adv Manuf Technol

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We proposed a new processing method to reduce the cutting force of the machining process effectively, as well as to improve tool life and machining process efficiency. The proposed method, called the milling-milling machining method, is a new form of composite machining that is similar to the turn-milling method. It combines the advantages of face milling and helical end-milling cutters and uses the synthesis motion of these kinds of cutters to complete surface processing. This technique effectively reduces cutting force and, thus, improves tool life and machining efficiency. The millingmilling machining method has the advantages of a large diameter face mill with a large milling area, a low cutting force, a stable and highly efficient cutting process that is similar to that of a helical end-milling cutter, and trochoidal milling. The outstanding characteristics of face milling and helical end-milling cutters can be applied directly to the milling-milling machining method. In addition, the proposed method has unique features. The up-down milling-milling machining method can offset a portion of the cutting forces. Apart from proposing the theory for the milling-milling machining method, we also designed new equipment, namely the planetary cutter, milling-milling driving head, and a computer numerically controlled milling-milling machine. We compared the proposed method and the common face milling method from the perspective of cutting forces. Experimental results show that the milling-milling machining method considerably reduces cutting forces compared with conventional methods.

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“…Azeem and Feng [23] improved the mechanistic cutting force model for multi-axis ball-end milling which was used for sculptured surface machining, and the generalized concept of characterizing the undeformed chip thickness for 3D cutter movement was proposed. Liu et al [24,25] presented an improved theoretical dynamic cutting force model for ball-end milling, and the size effect of the undeformed chip thickness and the influence of the effective rake angle were considered in the formulation of the differential cutting force based on the theory of oblique cutting. However, the cutting force model just provided a good prediction when the cutting speed was limited to a specified interval.…”

Section: Introductionmentioning

confidence: 99%

A new cutting force modeling method in high-speed milling of curved surface with difficult-to-machine material

Zhang

Wang

et al. 2015

Int J Adv Manuf Technol

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The high-speed milling technology for difficultto-machine material has come to be a hotspot in the industry field. Regarding the high-speed milling of Inconel 718 parts with curved surface, the variation of the geometric features of the curved surface will lead to the sharp fluctuation of the cutting force as well as the vibration of machine tool. In this way, it not only makes a severe impact on the surface machining quality and the tool life but also greatly affects the efficiency of the high-speed milling. For the milling force is an important physical concept to comprehensively reflect the milling process and the cutting speed is one of the main factors that affect the cutting force when the cutting volume is small in the high-speed milling of Inconel 718 parts with curved surface, a new cutting force modeling method is proposed based on the geometric characteristics of the curved surface and the spindle speed, which can be used to predict the cutting force fluctuation under different cutting speed. The experimental results show that the proposed cutting force model can effectively forecast the amplitude and the change trend of the cutting force. The achievements of this study will provide the theoretical basis for the optimization of machining parameters in high-speed milling of curved surface with difficult-to-machine material and enrich the processing and manufacturing theory for parts with curved surface.

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Improved dynamic cutting force model in peripheral milling. Part II: experimental verification and prediction

Cited by 28 publications

References 11 publications

Mathematical methodology for optimization of the clamping forces accounting for workpiece vibratory behaviour

Mathematical methodology for optimization of the clamping forces accounting for workpiece vibratory behaviour

The milling–milling machining method and its realization

A new cutting force modeling method in high-speed milling of curved surface with difficult-to-machine material

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