FRACTAL-BASED ANALYSIS OF THE VARIATIONS OF CUTTING FORCES ALONG DIFFERENT AXES IN END MILLING OPERATION

Fractals ◽  
2018 ◽  
Vol 26 (06) ◽  
pp. 1850089 ◽  
Author(s):  
HAMIDREZA NAMAZI ◽  
ALI AKHAVAN FARID ◽  
TECK SENG CHANG
Keyword(s):  
Fractal Dimension ◽  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Fractal Theory ◽  
Radial Force ◽  
Machining Conditions ◽  
Feed Force ◽  
Milling Operation ◽  
Force Signal

Analysis of cutting forces in machining operation is an important issue. The cutting force changes randomly in milling operation where it makes a signal by plotting over time span. An important type of analysis belongs to the study of how cutting forces change along different axes. Since cutting force has fractal characteristics, in this paper for the first time we analyze the variations of complexity of cutting force signal along different axes using fractal theory. For this purpose, we consider two cutting depths and do milling operation in dry and wet machining conditions. The obtained cutting force time series was analyzed by computing the fractal dimension. The result showed that in both wet and dry machining conditions, the feed force (along [Formula: see text]-axis) has greater fractal dimension than radial force (along [Formula: see text]-axis). In addition, the radial force (along [Formula: see text]-axis) has greater fractal dimension than thrust force (along [Formula: see text]-axis). The method of analysis that was used in this research can be applied to other machining operations to study the variations of fractal structure of cutting force signal along different axes.

FRACTAL-BASED ANALYSIS OF THE INFLUENCE OF CUTTING DEPTH ON COMPLEX STRUCTURE OF CUTTING FORCES IN ROUGH END MILLING

Fractals ◽  
2018 ◽  
Vol 26 (05) ◽  
pp. 1850068 ◽  
Author(s):  
HAMIDREZA NAMAZI ◽  
ALI AKHAVAN FARID ◽  
CHANG TECK SENG
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Fractal Structure ◽  
End Milling ◽  
Fractal Theory ◽  
Complex Structure ◽  
Cutting Depth ◽  
Force Signal ◽  
Dry Conditions ◽  
Machining Operations

Analysis of the cutting forces during machining operations is an important issue. The rough end mill with the serrated profile is broadly used for reduction of cutting forces during milling operation. Since cutting force changes in random behavior during end milling, in this paper we employ fractal theory to analyze the complex structure of cutting force signal. For this purpose, we investigated the influence of variations of cutting depth on variations of fractal structure of cutting forces in wet and dry machining conditions. The results of our analysis showed the variations of fractal structure of cutting forces between different cutting depths, in wet and dry conditions. The employed methodology in this research is not limited to rough end milling and can potentially be applied to other types of machining operations, where the variations of cutting forces is an important issue.

An AI-Based Model for Predicting Instananeous Cutting Force in End Milling

Manufacturing ◽  
2002 ◽  
Author(s):  
Hazim El-Mounayri ◽  
Vipul Tandon
Keyword(s):  
Cutting Force ◽  
Frequency Domain ◽  
Cutting Forces ◽  
End Milling ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Ann Model ◽  
Force Signal ◽  
Input Variables ◽  
Artificial Neural Network Ann

An Artificial Neural Network (ANN) model is developed to accurately predict the instantaneous cutting forces in flat end milling. A unique frequency domain approach is presented and is seen to simulate instantaneous cutting forces reasonably well. A set of eight input variables is chosen to represent the machining conditions and frequency domain parameters of the cutting force signal are generated. Three input parameters are varied, namely Feed, Speed and Depth of Cut. Four output parameters are suggested as a sufficient set to adequately reproduce the instantaneous cutting forces. Exhaustive experimentation is conducted to collect data (consisting of Fx, Fy, and Fz) to train and validate the model.

COMPLEXITY-BASED ANALYSIS OF THE INFLUENCE OF TOOL GEOMETRY ON CUTTING FORCES IN ROUGH END MILLING

Fractals ◽  
2018 ◽  
Vol 26 (05) ◽  
pp. 1850078 ◽  
Author(s):  
HAMIDREZA NAMAZI ◽  
ALI AKHAVAN FARID ◽  
CHANG TECK SENG
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Fractal Structure ◽  
End Milling ◽  
Complex Structure ◽  
Tool Geometry ◽  
Machining Parameters ◽  
End Mill ◽  
Force Signal ◽  
Machining Operations

It is known that geometry of cutting tool affects the cutting forces in machining operations. In addition, the value of cutting forces changes during machining operations and creates a chaotic time series (signal). In this paper, we analyze the variations of the complex structure of cutting force signal in rough end milling operation using fractal theory. In fact, we analyze the variations of cutting force signal due to variations of tool geometry (square end mill versus serrated end mill). In case of each type of end mill, we did the machining operation in wet and dry conditions. Based on the results, the fractal structure of cutting force signal changes based on the type of milling tool. We also did the complexity analysis using approximate entropy to check the variations of the complexity of cutting force signal, where the similar behavior of variations between different conditions was obtained. The method of analysis that was used in this research can be applied to other machining operations to study the influence of different machining parameters on variations of fractal structure of cutting force.

ANALYSIS OF CUTTING FORCES WHILE TURNING DIFFERENT MATERIAL

2020 ◽  
Vol 15 (4) ◽  
Author(s):  
Krishna Kumar M ◽  
Sangaravadivel P
Keyword(s):  
Cutting Force ◽  
Strain Gauge ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Tool Material ◽  
Radial Force ◽  
Machining Process ◽  
Depth Of Cut ◽  
Work Piece ◽  
Feed Force

The measurement of cutting forces in metal cutting is essential to estimate the power requirements, to design the cutting tool and to analyze machining process for different work and tool material combination. Although cutting forces can be measured by different methods, the measurement of cutting forces by a suitable dynamometer is widely used in industrial practice. Mechanical and strain gauge dynamometer are most widely used for measuring forces in metal cutting. The principle of all dynamometers is based on the measurement of deflections or strain produced from the dynamometer structure from the action of cutting force. In this project, a dynamometer is used to measure cutting force, feed force and radial force by using strain gauge accelerometer while turning different material in lathe. The dynamometer is a 500kg force 3- component system. As the tool comes in contact with the work piece the various forces developed are captured and transformed into numerical form system. In this project three forces of different materials such as aluminum, mild steel, brass, copper have been noted down. The forces on these materials with variation in speed and depth of cut are studied. Graphs are drawn on how these forces vary due to variation in speed.

Analysis of Characteristics of Dynamic and Static Component of the Cutting Force Signal in Turning

2013 ◽  
Vol 820 ◽  
pp. 166-169
Author(s):  
Yu Rong Jin ◽  
Xiao Zhong Ren ◽  
Bin Li
Keyword(s):  
Fractal Dimension ◽  
Cutting Force ◽  
Fractal Theory ◽  
Static Characteristic ◽  
Self Similarity ◽  
Characteristic Quantity ◽  
Static Component ◽  
Coated Tool ◽  
Dynamic Cutting Force ◽  
Force Signal

The characteristics of dynamic and static component of the cutting force signal were analyzed when the coated tool was used to cut gray cast iron. It is found that the whole and local of dynamic cutting force signal has self-similarity. Then the dynamic fractal dimension D was extracted by means of fractal theory, and the feature quantity M was extracted from the static cutting force signal. Research shows that the dynamic fractal dimension D of cutting force signal and static characteristic quantity M are varied with the cutting time. Their varying laws can be used to monitor the wear condition of coated tool effectively.

Prediction of cutting force and temperature rise in the end-milling operation

2006 ◽  
Vol 220 (10) ◽  
pp. 1577-1587 ◽  
Author(s):  
P Palanisamy ◽  
I Rajendran ◽  
S Shanmugasundaram ◽  
R Saravanan
Keyword(s):  
Cutting Force ◽  
Temperature Rise ◽  
End Milling ◽  
Milling Operation

Analytical Convolution Model of Cutting Forces in 3-D Ball End Milling

2001 ◽  
Author(s):  
Richard Y. Chiou ◽  
Bing Zhao
Keyword(s):  
Cutting Force ◽  
Frequency Domain ◽  
Cutting Forces ◽  
End Milling ◽  
Force Model ◽  
Three Dimensional Model ◽  
Calculation Algorithm ◽  
Ball End Milling ◽  
Convolution Model ◽  
Force Calculation

Abstract This paper presents an analytical convolution model of dynamic cutting forces in ball end milling of 3-D plane surfaces. The model takes into account the instantaneous slope on a sculptured surface to establish the chip geometry in cutting force calculation algorithm. A three-dimensional model of cutting forces in ball end milling is presented in terms of material properties, cutting parameters, machining configuration, and tool/work geometry. Based on the relationship of the local cutting force, chip load and engaged boundary, the total cutting force model is established via the angle domain convolution integration of the local forces in the feed, cross feed, axial direction, and inclination angle. The convolution integral leads to a periodic function of cutting forces in the angle domain and an explicit expression of the dynamic cutting force components in the frequency domain. Following the theoretical analysis, experimental study is discussed to illustrate the implementation procedure for force identification, and frequency domain data are presented to verify the analytical results.

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.

scholarly journals The Possibility of Applying Acoustic Emission and Dynamometric Methods for Monitoring the Turning Process

Materials ◽  
2020 ◽  
Vol 13 (13) ◽  
pp. 2926 ◽  
Author(s):  
Krzysztof Dudzik ◽  
Wojciech Labuda
Keyword(s):  
Acoustic Emission ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Radial Force ◽  
Diagnostic Methods ◽  
304L Stainless Steel ◽  
Turning Process ◽  
Physical Acoustics ◽  
Machined Surface ◽  
Feed Force

Ensuring optimal turning conditions has a huge impact on the quality and properties of the machined surface. The condition of the cutting tool is one of the factors to achieve this goal. In order to control its wear during the turning process, monitoring was used. In this study, the acoustic emission method and measure of cutting forces during turning were used for monitoring that process. The research was carried out on a universal lathe center (CU500MRD type) using a Kistler dynamometer with assembled removable insert CCET09T302R-MF by DIJET Industrial CO., LTD. A dynamometer allows to measure forces Fx (radial force), Fy (feed force) and Fz (cutting force). The turning process was performed on a shaft with 60 mm diameter made of 304L stainless steel. The AE research was carried at Physical Acoustics Corporation with the kit that includes: recorder USB AE Node, preamplifier, AE-sensor VS 150M and computer with dedicated software used for recording and analyzing AE data. The aim of this paper is to compare selected diagnostic methods: acoustic emission and cutting forces measurement for monitoring wear of cutting tool edge. Analysis of the research results showed that both selected methods of monitoring the turning process allowed the determination of the beginning of the tool damage process.

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