The prediction of cutting forces in the ball-end milling process—I. Model formulation and model building procedure

Feng, Hsi-Yung; Menq, Chia-Hsiang

doi:10.1016/0890-6955(94)90052-3

Cited by 135 publications

(65 citation statements)

References 14 publications

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“…Feng and Menq [16,29] attempted to determine the undeformed chip thickness for non-horizontal cutting motions of a ball-end mill by formulating and adding the specific contribution of the vertical feed component of the cutter to the undeformed chip thickness. This results in the same undeformed chip thickness values as those obtained using the proposed concept.…”

Section: Results and Comparisonmentioning

confidence: 99%

“…This direction was later adopted by several other researchers [11][12][13][14][15]. In contrast, Feng and Menq [16] formulated their mechanistic cutting force model for ball-end milling by defining the undeformed chip thickness as the radial distance between two consecutive cutting edge trajectories in the horizontal direction. This horizontal undeformed chip thickness determination direction was also employed in various studies on ball-end milling force modeling [17][18][19].…”

Section: Introductionmentioning

confidence: 99%

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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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Section: Results and Comparisonmentioning

confidence: 99%

Section: Introductionmentioning

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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“…In their work, the force model is based on the fundamental mechanics of orthogonal cutting and explicitly considers the effects of the shear angle, shear stress and friction angle. Other researchers [4][5][6][7] have studied the force model for the ball end mill with a mechanistic local force model, in which cutting constants are assumed to be proportional to the uncut chip area and are obtained through milling experiments. Unlike the mechanistic local force model, Sonawane and Joshi [8] presented a analytical force model for the ball-end milling of superalloy Inconel 718 considering strain, strain rate, and temperature dependence of work material shear strength by applying Johnson-Cook material mode.…”

Section: Introductionmentioning

confidence: 99%

Fourier Analysis of Milling Force for General Helical Cutters via Spacetime Convolution, Part 2: Applications for Common Cutters and Model Validation

Cm¹,

Jj²

2015

J Appl Mech Eng

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Part 2 of this study illustrates the applications of the frequency domain force model put forth in Part 1 for three common helical cutters: the square, taper, and ball end mills. The respective geometric and boundary functions required for the evaluation of the force spectra are derived by applying differential geometry to these three types of cutters including cutters of constant helix angle and constant helix lead. By virtue of the explict expression of Fourier coefficients of milling force, the differences between cutting forces generated by two cutters with constant helix angle and constant helix lead can be described quantitatively. In slot (or half slot) milling for the taper end mills with a constant helix angle and constant helix lead, the strategy for selecting axial depths of cut to reduce force pulsation is presented respectively. Also derived are the specific expressions for the average forces of these three helical cutters in common cutting configurations. Moreover, as an inverse application, a linear equation is formulated for the identification of six shearing and ploughing cutting constants from the measured average cutting forces for a general helical cutter. The frequency domain force model and the identification of the cutting constants are finally demonstrated and validated through experiments with all three types of milling cutters.

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“…Kurt et al (2010) experimentally investigated cutting forces which occurred during metal cutting, analyzed the effects on tools by means of ANSYS software and mathematically modeled the primary cutting force and the stresses using the acquired findings. Feng and Menq (1994) used dynamometer to measure experimental cutting forces and analytically fitted the force model. They designed a 2-D cutting force model, without considering cutting force along the axis of the cutting tool.…”

Section: Introductionmentioning

confidence: 99%

Predictive Models for Cutting Force in Turning Tools Based on Response Surface Methodology

Ezeanyagu¹,

Okafor²,

Omenyi³

2018

Review of Industrial Engineering Letters

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Article HistoryThis paper presents the development of predictive models for feed cutting force component when turning mild steel rods at 90owith cutting tools in a local lathe shop. The predictive models were formulated with cutting condition kept dry. Experimental plan was based on Rotatable Central Composite Design (RCCD) and cutting forces generated in the feed direction was measured using a dynamometer. Analysis was performed on the generated data for both tool-work piece combination and feed rate and its squared effect is found to influence the response variable greatly. However, other factors and their interactions provide secondary contributions. Next, the predicted models were compared with the measured feed cutting forces and an agreement established. The coefficient of determination R 2 values of the models gave 76% and 79% respectively, which indicate that the predicted models could adequately describe the process within the conditions that were being studied. Contribution/Originality:This study contributes in the existing literature by proffering simplistic and cost effective cutting force model based on a planned experiment and statistical methodology.

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The prediction of cutting forces in the ball-end milling process—I. Model formulation and model building procedure

Cited by 135 publications

References 14 publications

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

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

Fourier Analysis of Milling Force for General Helical Cutters via Spacetime Convolution, Part 2: Applications for Common Cutters and Model Validation

Predictive Models for Cutting Force in Turning Tools Based on Response Surface Methodology

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