Study of the Classification of Cutting Forces and the Build of Accurate Milling Force Model in End Milling

Abstract

A new approach is proposed to model the milling force based on the cutting force shape characteristics in end milling. The relationship between the cutting force shape characteristics and the cutting depths is analyzed and milling forces are classified into 10 types according to the combination of cutting depths. Further, force indices are extracted and then the real cutting depths are detected based on the changes of force curve characteristics via the force indices in end milling process. Then, bring forward a method of modeling cutting force based on the different types, and the use of real cutting depth makes the model to be more accurately. More important, experiments designed on the classification of milling forces strengthen the pertinence, and makes the experiment data more reliable. The approach is validated through experiments on aluminum alloy 7050-T7451.

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

“…Linear relationship between average milling force and feed rate per tooth is obtained through linear regression analysis to separate shear and plough force, and obtain shear and plough effect coefficients. Kang and Yin et al [176][177][178] used the average milling force to calculate the cutting force coefficient in the centralized cutting force model. They also established the quadratic polynomial relationship between the milling force coefficient and spindle speed, feed rate, and radial and axial cutting depth through orthogonal test method and regression analysis.…”

“…In these [167] 1995 Tool parameters [168] Helix angle [183] 1997 Cutting force signals [165] 1999 Cutting system deflections [195] 2001 Chip flow angle [116] 2002 Feed; cutter deflection; cutter runout. [174] 2003 Tool parameters [157] Tool parameters [150] Cutter flexibility [196,197] 2004 Deflection; runout [175] 2007 Cutting depth [176,177] Cutter deflection [198] 2008 Milling parameters [188,199] Cutter runout [191] 2009 Tool parameters [178] ALE formulation Cutter runout [51,154] 2011 Cutting geometry [187] 2012 Feed per tooth and cutting speed [179] 2014 Milling parameters [164,183] Chip thickness [194] 2015 Optimization technique [184,185] 2016 Material data [200] 2018 Axial depth; radial width; feed rate [180,181,201] models, accurately predicting the chip force component at the peak or valley position is difficult because of the great difference between the average and instantaneous chip thicknesses. When the instantaneous cutting force coefficient is expressed as an exponential function of the instantaneous cutting thickness, the prediction accuracy of the instantaneous milling force can be improved and the experimental amount of the identification of the cutting coefficient can be reduced.…”

Corner milling force prediction and improvement method of aviation thin-walled structural parts

“…Wan [5] introduced the cutter / workpiece deflections and cutting contact angle into the calculation of milling force when calculating instantaneous chip thickness. Kang [6] extended the average force model of Kline and established the average cutting force model under different cutting parameters. The cutting force coefficient was expressed as a polynomial form of spindle speed, cutting width and cutting depth per tooth feed.…”

The estimation of cutting force coefficients in milling of thin-walled parts using cutter with different tooth radii

“…For example, cutting force coefficients in milling are expressed as nonlinear functions of uncut chip thickness in literatures. 7–13 Considering the dependence of other milling parameters on cutting force coefficients in the literatures, 14–16 cutting force coefficients are expressed as quadratic functions of milling speed, uncut chip thickness, axial and radial milling depth.…”