Investigation of the milling stability based on modified variable cutting force coefficients

Liu, Xianli; Gao, Haining; Yue, Caixu; Li, Rongyi; Jiang, Nan; Yang, Lin

doi:10.1007/s00170-018-1780-9

Cited by 20 publications

(10 citation statements)

References 27 publications

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“…Using at least two fz, the six equations system is solved, obtaining the force coefficient. To improve the accuracy of the values, Liu et al [105] used three spline interpolation. There are alternative methods to calculate Kqc and Kqe such as that of Du et al [69], who used the Fourier form to determine the milling forces and then the force coefficient.…”

Section: Analytic Modelsmentioning

confidence: 99%

“…For instance, Olvera et al [39], Germashev et al [40] and Guo et al [16] studied the runout and helix angle effect in a SLD, while Urbikain et al [149] and Jing et al [20] compared the effect of the tool position. Liu et al [105] focused their research in the effect of the radial depth of cut and Qu et al [25] analyzed the feed rate effect. Feng et al [18] evaluated the effect of velocity-dependent mechanisms to obtain a closer SLD, obtaining better results than the ones using a plowing force coefficient.…”

Section: Computational Solutionsmentioning

confidence: 99%

“…Tian et al [45] used an eigenvalue sensitivity method to improve machining stability and the final surface finishing. Liu et al [105] applied different filters to the cutting force in order to analyze the cutting coefficient behavior and its effect on the stability of the system. Liu et al [108,109] used a Q-factor method to identify the change on the machining operation between the stable and chatter regions.…”

Section: Industrial Approachmentioning

confidence: 99%

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Thin-Wall Machining of Light Alloys: A Review of Models and Industrial Approaches

et al. 2019

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Thin-wall parts are common in the aeronautical sector. However, their machining presents serious challenges such as vibrations and part deflections. To deal with these challenges, different approaches have been followed in recent years. This work presents the state of the art of thin-wall light-alloy machining, analyzing the problems related to each type of thin-wall parts, exposing the causes of both instability and deformation through analytical models, summarizing the computational techniques used, and presenting the solutions proposed by different authors from an industrial point of view. Finally, some further research lines are proposed.

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Section: Analytic Modelsmentioning

confidence: 99%

Section: Computational Solutionsmentioning

confidence: 99%

Section: Industrial Approachmentioning

confidence: 99%

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Thin-Wall Machining of Light Alloys: A Review of Models and Industrial Approaches

et al. 2019

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“…Ball end milling cutter is widely used in the complex surface finishing of important parts in aerospace, die and automobile industry because of its strong adaptability. Due to the high surface quality requirements of these products, extensive research work has been carried out around this milling process [3,4]. The cutting edges geometry of the ball-end milling cutter is complex, and the contact point between the cutting edges and the workpiece is constantly changing during milling.…”

Section: Introductionmentioning

confidence: 99%

Simulation of Surface Topography Considering Cut-in Impact and Tool Flank Wear

et al. 2019

Self Cite

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Milling is a kind of interrupted cutting. When the tool cuts into the workpiece, it is often accompanied by instantaneous impact, which results in impact vibration of the milling system. Meanwhile, tool wear will occur gradually on flank face with the cutting progress. The impact vibration and tool wear affect the morphological characteristics of machined surfaces. In the present work, the instantaneous impact force is obtained by introducing the italic impact model of single degree of freedom, and the free vibration in the x and y directions under the impact force is obtained by combining the damped vibration equation. The cutting vibration in the x and y directions is obtained by solving the dynamic equation of the milling system with the fourth-order Runge–Kutta method. The equation of the cutting edge is modified according to the tool flank wear, and the machined surface topography considering the dynamic characteristics of cutting system and tool flank wear is obtained by combining the Z-MAP algorithm. The verification milling experiment was carried out on the hardened steel Cr12MoV workpiece. The simulation results are in good agreement with the experimental results. The research results have important guiding significance for the reasonable selection of processing parameters in actual production.

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“…Vibrations-chatter and forced vibrations-can directly affect the final roughness of parts, increasing their value and forcing manufacturers to make reprocessing steps, therefore increasing the operational cost [8,9]. In order to avoid them, chatter influence is studied using stability lobe diagrams (SLD), a representation tool that commonly relates the stability areas of machining with the feed rate, the spindle speed, the depth of cut, or the tool position [10][11][12][13][14], and forced vibrations can be studied through dynamic models. In this 2 of 11 case, the applied force is studied to reduce the dynamic deflection of the part.…”

Section: Introductionmentioning

confidence: 99%

Effects of Machining Parameters on the Quality in Machining of Aluminium Alloys Thin Plates

Sol

Rivero

Gámez

2019

Metals

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Nowadays, the industry looks for sustainable processes to ensure a more environmentally friendly production. For that reason, more and more aeronautical companies are replacing chemical milling in the manufacture of skin panels and thin plates components. This is a challenging operation that requires meeting tight dimensional tolerances and differs from a rigid body machining due to the low stiffness of the part. In order to fill the gap of literature research on this field, this work proposes an experimental study of the effect of the depth of cut, the feed rate and the cutting speed on the quality characteristics of the machined parts and on the cutting forces produced during the process. Whereas surface roughness values meet the specifications for all the machining conditions, an appropriate cutting parameters selection is likely to lead to a reduction of the final thickness deviation by up to 40% and the average cutting forces by up to a 20%, which consequently eases the clamping system and reduces machine consumption. Finally, an experimental model to control the process quality based on monitoring the machine power consumption is proposed.

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Investigation of the milling stability based on modified variable cutting force coefficients

Cited by 20 publications

References 27 publications

Thin-Wall Machining of Light Alloys: A Review of Models and Industrial Approaches

Thin-Wall Machining of Light Alloys: A Review of Models and Industrial Approaches

Simulation of Surface Topography Considering Cut-in Impact and Tool Flank Wear

Effects of Machining Parameters on the Quality in Machining of Aluminium Alloys Thin Plates

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