Surface error shape identification for 3-axis milling operations

Morelli, Lorenzo; Grossi, Niccolò; Scippa, Antonio; Campatelli, Gianni

doi:10.1016/j.procir.2021.02.016

Cited by 3 publications

(6 citation statements)

References 10 publications

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“…In this work, all the shapes which the total cutting force F (i.e., resultant of cutting force in the x-y plane, as shown in Figure 1) could assume are analyzed and a comprehensive classification is provided, starting from a single fluted endmill (N = 1) to a generical multiple-fluted endmill (N > 1), as partially presented in [7,28]. Each shape is identified by key points, whose coordinates are expressed through the angular position (i.e., key angle) and a binary value (m) which is related to the magnitude of the cutting and defined in this work as: 𝑚𝑚= 1 when cutting force is maximum 𝑚𝑚=0 when cutting force is minimum (1) These formulations are valid in one period, wide as the tool pitch angle (ϕz), which marks the periodicity of the cutting force (neglecting tool run-out).…”

Section: Methodsmentioning

confidence: 99%

“…The proposed formulations start from the basic angles already presented by other authors [7,28]. The axial engagement angle α sw is related to ap and the endmill's geometry following the equations:…”

Section: Key Anglesmentioning

confidence: 99%

“…The interaction forces between tool and workpiece, known as cutting forces, are an essential input for several of these approaches since they can reveal the effects of different key aspects of the process, such as tool wear [2], engagement conditions [3], vibrations [4], surface error [5,6]. In milling such cutting forces are not constant during the process and their shape and magnitude change significantly with cutting process parameters [7]. Different cutting force models have been proposed in the literature, and most of them relate cutting forces to the chip thickness by utilizing cutting force coefficients [8][9][10].…”

Section: Introductionmentioning

confidence: 99%

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Forces Shapes in 3-Axis End-Milling: Classification and Characteristic Equations

Grossi¹,

Morelli²,

Venturini³

et al. 2021

JMMP

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In 3-axis milling, cutting force analysis represents one of the main methods to increase the quality and productivity of the process. In this context, cutting force shape gives information of both monitoring and prediction of the cutting process. However, the cutting force shape is not unique, and it changes according to the cutting strategy, tool geometry, and cutting parameters. This paper presents a comprehensive approach to predict and classify cutting force shapes in 3-axis milling operations. In detail, the proposed approach starts by classifying the cutting force shapes for a single fluted endmill (i.e., single flute force shape), and, considering how the single flute force shapes may overlap one another, it extends the classification to a general multiple-fluted endmill. Moreover, the method provides, through analytical equations, angles, and magnitude dimensionless parameters of each key point, describing each shape classified. Finally, the proposed approach was experimentally validated through several milling tests in different cutting conditions.

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Section: Methodsmentioning

confidence: 99%

Section: Key Anglesmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Forces Shapes in 3-Axis End-Milling: Classification and Characteristic Equations

Grossi¹,

Morelli²,

Venturini³

et al. 2021

JMMP

Self Cite

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“…The analysis of forces in the milling process provides information on the mechanics of the cutting process, taking into account the properties of the workpiece material and tool geometry. To model the cutting forces for end milling, a mechanistic force model is applied, which has been proven in previous research [34][35][36]. This model relates the cutting force components to the undeformed chip thickness.…”

Section: Dmentioning

confidence: 99%

“…where a e is the radial depth of cut, a p is the axial depth of cut, D is the tool's diameter, and α el = 45 o is the cutter's helix angle parameters. Indeed, the angle θ = ∅ in + α sw represents angular positions where the cutting edge is fully involved in the cut, thus identifying a maximum cutting force [34]. The analysis of forces in the milling process provides information on the mechanics of the cutting process, taking into account the properties of the workpiece material and tool geometry.…”

Section: Dmentioning

confidence: 99%

Analysis of Cutting Forces and Geometric Surface Structures in the Milling of NiTi Alloy

Kowalczyk

2024

Materials

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This paper presents a study of the total cutting force used and selected parameters of the geometric structure of the surface (e.g., Sa, Sz) during the end milling process of NiTi alloy. The input parameters included are cutting speed (vc), feed per tooth (fz), and radial depth of cut (ae). A Box–Behnken experimental design was employed to conduct the research. The obtained experimental results were utilized within the framework of a response surface methodology (RSM) to develop mathematical and statistical models capable of predicting cutting force components and selected 3D surface parameters. These models provide valuable insights into the relationships between the cutting parameters and the output variables, facilitating the optimization of the NiTi alloy milling process. The findings of this study contribute to a better understanding of the behavior of NiTi alloy during the milling process and offer information for process optimization. By employing a Box–Behnken experimental design, it was possible to investigate the effects of different parameter combinations on the components of total cutting force and selected 3D surface parameters according to ISO 25178, thus aiding in the identification of optimal milling conditions to achieve desired outcomes in the machining of NiTi alloy.

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Quality of Machined Surface and Cutting Force When Milling NiTi Alloys

Kowalczyk,

Tomczyk

2024

Materials

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The machining of shape memory alloys, such as NiTi, presents challenges due to their specific physical, chemical, and mechanical properties. This study investigated the effect of the helix angle of milling tools—both uncoated and coated—on the cutting forces and the surface roughness of the milling process for a NiTi alloy. Experiments were conducted using the tools with and without coatings at various helix angles (20°, 30°, and 40°) and under different machining conditions. Optimization of the process was employed the Taguchi method to identify the best combination of the corresponding parameters. The results of the cutting force and the surface roughness measurements were analyzed and discussed in the context of optimizing the cutting conditions to achieve the desired outcomes. The results show that the lowest surface roughness values (Sa = 0.301 μm and Sz = 3.41 μm) were achieved with the coated tool at a helix angle of 30°, a feed per tooth of 0.02 mm, and a cutting speed of 45 m/min, while the lowest cutting force (F = 143.6 N) was observed with the coated tool at a cutting speed of 55 m/min, helix angle of 40°, and feed per tooth of 0.02 mm. This research provides valuable insights for industrial applications requiring the precise machining of NiTi in terms of the cutting forces and the surface quality. The findings reveal that the presence of the coating, along with an increase in the helix angle, significantly reduces the cutting forces, positively influencing the quality of the machined surface.

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Surface error shape identification for 3-axis milling operations

Cited by 3 publications

References 10 publications

Forces Shapes in 3-Axis End-Milling: Classification and Characteristic Equations

Forces Shapes in 3-Axis End-Milling: Classification and Characteristic Equations

Analysis of Cutting Forces and Geometric Surface Structures in the Milling of NiTi Alloy

Quality of Machined Surface and Cutting Force When Milling NiTi Alloys

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