The simulation of cutting force of free-form surface machining with ball-end milling cutter

Shi, Lei; Liu, En Fu; Zhang, Yi; Chen, Peng; Li, Zong Bin

doi:10.1109/ieem.2009.5373028

Cited by 3 publications

(1 citation statement)

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“…The empirical model of milling force is a model derived by fitting milling test data and is mainly used to predict the magnitude of milling force. Ding [16] and Lei [17] used orthogonal tests to obtain the milling force coefficients and established an empirical model of milling force. Bergmann [18] developed a nonlinear empirical model of milling force and improved the prediction of stability limits achieved by parameterizing a milling force model for stability analysis.…”

Section: Introductionmentioning

confidence: 99%

Milling Mechanism and Chattering Stability of Nickel-Based Superalloy Inconel 718

Zheng,

Zhang,

Qiao

2023

Materials

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Nickel-based superalloy Inconel 718 is widely used in the aerospace industry for its excellent high-temperature strength and thermal stability. However, milling Inconel 718 presents challenges because of the significantly increased cutting force and vibration, since Inconel 718 is a typical difficult-to-machine material. This paper takes the milling process of Inconel 718 as the research object, initially, and a milling force model of Inconel 718 is established. Subsequently, the finite element analysis method is used to analyze the stress field, temperature field, and milling force in the milling process of Inconel 718. Building upon this, a dynamic equation of the milling of Inconel 718 is established, and based on the modal experiment, stability lobe diagrams are drawn. Furthermore, milling experiments on Inconel 718 are designed, and the results calculated using the milling force model and finite element analysis are verified through comparison to the experimental results; then, the fmincon optimization algorithm is used to optimize the processing parameters of Inconel 718. Eventually, the results of the multi-objective optimization illustrate that the best processing parameters are a spindle speed of 3199.2 rpm and a feed speed of 80 mm/min with an axial depth of cut of 0.25 mm. Based on this, the best machining parameters are determined, which point towards an improvement of the machining efficiency and quality of Inconel 718.

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Section: Introductionmentioning

confidence: 99%

Milling Mechanism and Chattering Stability of Nickel-Based Superalloy Inconel 718

Zheng,

Zhang,

Qiao

2023

Materials

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Milling Mechanism and Chattering Stability of Nickel-Based Superalloy Inconel718

Zheng¹,

Zhang²,

Qiao³

2023

Preprint

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Nickel-based Superalloy Inconel 718 is widely used in the aerospace industry for its excellent high-temperature strength and thermal stability. However, milling Inconel 718 presents challenges due to significantly increased cutting force and vibration, which is a typical difficult-to-machine material. This paper focuses on the milling process of Inconel 718, establishing a milling force model to analyze the force trends under various processing parameters. Finite element analysis is employed to study the stress and temperature fields during milling. Dynamic equations for milling Inconel 718 are developed, and stability lobe diagrams are generated based on modal experiments. Milling experiments on Inconel 718 validate the milling force model and finite element analysis results. The fmincon optimization algorithm is utilized to identify the optimal machining parameters for Inconel 718. Through this research, valuable insights into enhancing the efficiency and quality of Inconel 718 machining are provided. This study contributes to a deeper understanding of Inconel 718 milling behavior, offering crucial guidance for more efficient machining processes.

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Analysis of automated surface roughness parameter support systems based on dynamic monitoring

Gimadeev

2022

Vestnik Donskogo gosudarstvennogo tehničeskogo universiteta

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Introduction. Domestic and foreign works on the milling of complex-profile surfaces with a ball-end tool were analyzed. Methods of surface quality control and ways to provide amplitude parameters of roughness, based on research data and field experiments, were considered. Theoretical provisions on the determination of cutting forces and the results of vibroacoustic diagnostics were presented.Materials and Methods. The methods of correlation analysis, comparison and generalization of the results were applied. The data were calculated at different tool angles, taking into account the instantaneous cutting forces, and were fixed in the range of values of the variable feed per tooth (fz) and the angle of inclination of the surface (γ). The vibroacoustic diagnostic data and theoretical data of the presented model at different tool inclination angles were verified by experiment. Consequently, such methods can be used to predict surface roughness parameters.Results. The relationship between cutting forces, tool inclination angle, and vibroacoustic diagnostics data was found. A model of the cutting force and tool displacements was formulated taking into account the inclination of the surface. The optimal range of the inclination angle of the tool to the surface to be machined, at which the minimum values of the amplitude parameters of roughness were achieved, was determined. The sound vibrations obtained empirically, presented in spectral and wave forms, were in good agreement with data from other sources. This allowed us to conclude about the feasibility of forecasting and monitoring roughness parameters in real time through acoustics.Discussion and Conclusions. It was established that the growth of forces in the direction ae(X) and fz(Y) was observed at γ > 40°. This was due to the distribution of the components of the cutting force along the cutting edge and depended on the inclination of the surface. The amplitude parameters decreased when the angle increased from 10 to 40 degrees. The found interrelations of force analysis, processing directions, and vibroacoustic diagnostics have validated the use of vibroacoustic diagnostics to predict surface roughness. Acoustic diagnostics, regardless of the layout of technological equipment, enables to quickly adjust the sound device and assess the impact of cutting modes on roughness parameters.

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The simulation of cutting force of free-form surface machining with ball-end milling cutter

Cited by 3 publications

References 10 publications

Milling Mechanism and Chattering Stability of Nickel-Based Superalloy Inconel 718

Milling Mechanism and Chattering Stability of Nickel-Based Superalloy Inconel 718

Milling Mechanism and Chattering Stability of Nickel-Based Superalloy Inconel718

Analysis of automated surface roughness parameter support systems based on dynamic monitoring

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