A Cutting Force Model for a Waved-Edge End Milling Cutter

2003 ◽  
Vol 21 (6) ◽  
pp. 403-410 ◽  
Author(s):  
B. Zhang ◽  
Z. Li ◽  
D. Liu ◽  
L. Zheng ◽  
Z. Zhang ◽  
...  
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Force Model ◽  
Cutting Force Model ◽  
Milling Cutter

Analysis of Cutting Force in Elastomer End-Milling

2017 ◽  
Vol 11 (6) ◽  
pp. 958-963
Author(s):  
Koji Teramoto ◽  
◽  
Takahiro Kunishima ◽  
Hiroki Matsumoto
Keyword(s):  
Parameter Identification ◽  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Process Models ◽  
Force Model ◽  
Cutting Force Model ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
The Stability

Elastomer end-milling is attracting attention for its role in the small-lot production of elastomeric parts. In order to apply end-milling to the production of elastomeric parts, it is important that the workpiece be held stably to avoid deformation. To evaluate the stability of workholding, it is necessary to predict cutting forces in elastomer end-milling. Cutting force prediction for metal workpiece end-milling has been investigated for many years, and many process models for end-milling have been proposed. However, the applicability of these models to elastomer end-milling has not been discussed. In this paper, the characteristics of the cutting force in elastomer end-milling are evaluated experimentally. A standard cutting force model and its parameter identification method are introduced. By using this cutting force model, measured cutting forces are compared against the calculated results. The comparison makes it clear that the standard cutting force model for metal end-milling can be applied to down milling for a rough evaluation.

Dynamic Response Analysis in End Milling Using Pretwisted Beam Finite Element

1995 ◽  
Vol 117 (1) ◽  
pp. 1-10 ◽  
Author(s):  
C.-L. Liao ◽  
J.-S. Tsai
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Present Model ◽  
End Milling ◽  
Chip Thickness ◽  
Beam Element ◽  
Force Model ◽  
Milling Cutter ◽  
Tool Deflections ◽  
Cutting System

This paper develops an analytical model to estimate the dynamic responses in end milling, i.e., dynamic milling cutter deflections and cutting forces, by using the finite element method along with an adequate end milling cutting force model. The whole cutting system includes spindle, bearings and cutter. The spindle is structurally modeled with the Timoshenko-beam element, the milling cutter with the pretwisted Timoshenko-beam element due to its special geometry, and the bearings with lumped springs and dampers. Because the damping matrix in the resulting finite element equation of motion for the whole cutting system is not of proportional damping due to the presence of bearing damping, we use state-vector approach and convolution integral to find the solution of equations of motion. To assure the accuracy of dynamic response predication, the associated cutting force model should be sufficiently precise. Since the dynamic cutting force is proportional to the chip thickness, a quite accurate algorithm for the calculation of chip thickness variation due to tool geometry, runout and spindle-tool vibration is developed. A number of dynamic cutting forces and tool deflections obtained from the present model for various cutting conditions are compared with the experimental and analytical results available in the literature, and good agreement is demonstrated for these comparisons. Therefore the present model is useful for the prediction of end milling instability. Also, the tool deflections obtained by using the pretwisted beam element are found smaller than those by straight beam elements without pretwist angle. Hence, neglecting the pretwist angle in the structural model of milling cutter may overestimate the tool deflections.

Computer Design of a Minimum Vibration Face Milling Cutter Using an Improved Cutting Force Model

1976 ◽  
Vol 98 (3) ◽  
pp. 807-810 ◽  
Author(s):  
P. Doolan ◽  
M. S. Phadke ◽  
S. M. Wu
Keyword(s):  
Cutting Force ◽  
Rectangular Pulse ◽  
General Purpose ◽  
Face Milling ◽  
Force Model ◽  
Computer Design ◽  
Cutting Force Model ◽  
Milling Cutter

An improved cutting force model is integrated in the design of a minimum vibration face milling cutter. The cutting force of a blade is approximated by a rectangular pulse whose height is governed by the blade spacing. Specific examples of a special purpose and a general purpose cutter are given and their performances are evaluated.

Research on Feedrate Optimization Based on Cutting Force Model with Double Effect for the Ball-End Milling

2011 ◽  
Vol 291-294 ◽  
pp. 2965-2969
Author(s):  
Yu Jun Cai ◽  
Hua Shen ◽  
Tie Li Qi
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Double Effect ◽  
Machining Process ◽  
Force Model ◽  
Optimization Strategy ◽  
Cutting Force Model ◽  
Ball End Mill ◽  
Ball End Milling ◽  
Feedrate Optimization

A new cutting force model of ball-end mill with double effect is developed through analysing the machining process by using differential geometry. The cutting force model is needed to be revised for the component force in Z direction because of the offset to the actual results. The cutting force and the ball-end milling force coefficients can be given with numerical method. A feedrate optimization strategy is also proposed based on the developed cutting force model and tested effectively.

Cutting Force Prediction for Generalized Cornering Milling Process

2011 ◽  
Vol 188 ◽  
pp. 404-409 ◽  
Author(s):  
Xue Yan ◽  
Hua Tao ◽  
D.H. Zhang ◽  
B.H. Wu
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Milling Process ◽  
Force Model ◽  
Cutting Force Model ◽  
Cutting Force Prediction ◽  
Geometric Relationship ◽  
The Mathematical Model ◽  
Good Agreement

A developed method to predict the cutting forces in end milling of generalized corners is proposed in this paper. The cornering milling process is divided into a series of cutting segments with different cutting states. The mathematical model of the geometric relationship between cutter and the corner profile is established for each segment. Cutting forces is predicted by introducing the classical cutting force model. The computational results of cutting forces are in good agreement with experimental data.

Stability Predictions for End Milling Operations With a Nonlinear Cutting Force Model

2009 ◽  
Vol 131 (6) ◽  
Author(s):  
Alex Elías-Zúñiga ◽  
Jovanny Pacheco-Bolívar ◽  
Francisco Araya ◽  
Alejandro Martínez-López ◽  
Oscar Martínez-Romero ◽  
...  
Keyword(s):  
Experimental Data ◽  
Cutting Force ◽  
End Milling ◽  
Stability Conditions ◽  
Force Model ◽  
Process Stability ◽  
Cutting Force Model ◽  
Stability Lobes ◽  
Milling Operations ◽  
The Stability

The aim of this paper is to obtain the stability lobes for milling operations with a nonlinear cutting force model. The work is focused on the generation of stability lobes based on a formulation with Chebyshev polynomials and the semidiscretization method, considering a nonlinear cutting force model. Comparisons were conducted between experimental data at 5% radial immersion with aluminum workpiece and predictions based on Chebyshev and semidiscretization. In all cases, the use of nonlinear cutting force model provides better prediction of process stability conditions.

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