Cutting Force Prediction of Stainless Steel in High-Speed Milling

2012 ◽  
Vol 538-541 ◽  
pp. 1369-1372
Author(s):  
Xiao Zheng Xie ◽  
Yun Ping Yao ◽  
Rong Zhen Zhao ◽  
Wu Yin Jin
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Productive Efficiency ◽  
Experimental Result ◽  
Force Model ◽  
Cutting Force Prediction ◽  
High Speed Milling ◽  
Geometry Model ◽  
Milling Force Model ◽  
Process Material

According to the components, mechanical properties of difficult-to-process material (26NiCrMoV145)as well as characteristics of high-speed machining, modelling and prediction of cutting force in high-speed milling is studied. Based on geometry model of ball end mill edge line, milling force model of helical ball milling cutter is established by theoretical analysis and empirical coefficient. Then, simulation prediction of cutting forece is conducted under different circumstances. The experimental result shows that the predicted cutting force is consistent with experimental data and the established model is reasonable. The article contributes to the milling of difficult-to-process material, which improves security and productive efficiency in processing.

An Improved Tool Path Model Including Gyroscopic Effect for Instantaneous Cutting Force Prediction in High-Speed Milling

2011 ◽  
Vol 418-420 ◽  
pp. 840-843
Author(s):  
Qing Hua Song ◽  
Xing Ai
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Tool Path ◽  
Milling Process ◽  
Path Model ◽  
Force Model ◽  
Cutting Force Model ◽  
Gyroscopic Effect ◽  
Cutting Force Prediction ◽  
High Speed Milling

The efficiency of the high-speed milling process is often limited by the occurrence of chatter. In order to predict the occurrence of chatter, accurate models are necessary. With the speed increasing, gyroscopic effect plays an important pole on the system behavior, including dynamic characteristic and rotating behavior. Considering the influence of gyroscopic effect on rotating behavior, an updated model for the milling process is presented which features as model of the equivalent profile of tool. In combination with this model, a nonlinear instantaneous cutting force model is proposed. The use of this updated equivalent profile of tool results in significant differences in the static uncut thickness compared to the traditional model.

Transient Dynamic Analysis of the Matching of Lengthened Shrink-Fit Holder and Cutter in High-Speed Milling

2010 ◽  
Vol 97-101 ◽  
pp. 1819-1822 ◽  
Author(s):  
Hou Ming Zhou ◽  
Jian Xin Deng ◽  
Zhen Yu Zhao ◽  
Shi Ping Yang
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
Back Propagation ◽  
Force Model ◽  
Milling Force ◽  
Transient Dynamic Analysis ◽  
High Speed Milling ◽  
Transient Dynamic ◽  
Shrink Fit ◽  
Milling Force Model

Finite element model of the matching of lengthened shrink-fit holder (LSFH) and cutting tool is established and a milling force model is developed to predict the transient milling force exactly using back propagation neural network (BPNN). Subsequently, the transient dynamic characteristic of matching of LSFH and cutting tool is analyzed and the simulation result is obtained. Finally, the simulation result is verified with practical measurement and the results fit very well. The studies are important to optimum design and select the lengthened shrink-fit holder in high speed milling.

Experimental Study and Modeling of Milling Force during High-Speed Milling of SiCp/Al Composites Using Regression Analysis

2011 ◽  
Vol 188 ◽  
pp. 3-8
Author(s):  
Shu Tao Huang ◽  
X.L. Yu ◽  
Li Zhou
Keyword(s):  
Regression Analysis ◽  
Feed Rate ◽  
High Speed ◽  
Volume Fraction ◽  
Linear Regression Analysis ◽  
Force Model ◽  
Milling Force ◽  
High Speed Milling ◽  
Milling Forces ◽  
Milling Force Model

SiCp/Al composites with high volume fraction and large particles are very difficult to machine. In this present study, high-speed milling experiments were carried out on the SiCp/Al composites by the three factors-levels orthogonal experiment method, and multiple linear regression analysis was employed to establish milling force model. The results show that the milling forces decrease with the increasing of the milling speed or increase with the increasing of the feed rate and depth of milling. The influence of milling depth on the milling forces in directions of x, y is the most significant, while the influence of the feed rate on the z-milling forces are the most significant. The calculation values from the milling force model are consistent with the experimental values. The results will provide a reliable theoretical guidance for milling of SiCp/Al composites, and it is feasible to predict the milling force during the milling of SiCp/Al by using this model.

Stability of High Speed Milling Based on Instantaneous Cutting Force

2012 ◽  
Vol 152-154 ◽  
pp. 404-408
Author(s):  
Hong Liang Zhou ◽  
Wei Xiao Tang ◽  
Qing Hua Song
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
End Milling ◽  
Element Model ◽  
Face Milling ◽  
Force Model ◽  
Dynamics Model ◽  
High Speed Milling ◽  
High Productivity ◽  
Rotating Speed

High-speed milling (HSM) has advantages in high productivity high precision and low production cost. Thus it can be widely used in the manufacture industry. However, when the speed of spindle-tool reaches a higher speed range, the gyroscopic effect will become an important part of its stable milling. In this paper, a dynamics model of HSM system was proposed considering the influence of gyroscopic moment due to high rotating speed of end milling. Finite element model (FEM) is used to model the dynamics of a spindle-milling system. It obtains the trajectory of central point in face milling with considering gyroscopic effects through the dynamics model at high speeds. Then the cutting force model will be corrected by the trajectory of face milling. Then the stability lobes diagrams (SLD) was elaborated. Cutting thickness effects have non-negligible impact on stability limitation.

scholarly journals Analysis of Cutting Forces From Conventional to High-Speed Milling with Straight and Helical-Flute Tools for Flat-End Milling Incorporating the Effect of Tool Runout

2021 ◽  
Author(s):  
Mehmet AYDIN ◽  
Uğur Köklü
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
End Milling ◽  
Spindle Speed ◽  
Force Model ◽  
Workpiece Material ◽  
High Speed Milling ◽  
Tool Runout ◽  
Flat End Milling

Abstract This paper presents a systematic study to analyze the dependence of cutting forces on tool geometry, workpiece material and cutting parameters such as spindle speed, tool engagement and cutting direction in flat-end milling with tool runout. The cutting forces are determined according to a mechanistic force model considering the trochoidal flute path to calculate the undeformed chip thickness, and average cutting force and linear regression model are applied for identifying the coefficients of the force model. A series of milling processes are conducted on AZ31 Magnesium (Mg) alloy and titanium alloy (Ti6Al4V) to analyze the instantaneous cutting force curves, amplitudes of cutting forces and peak forces over a wide range of spindle speeds from conventional to high-speed milling. It is demonstrated that the values of the cutting force coefficients are higher at conventional spindle speed and decrease with an increase in spindle speed, especially when machining Ti6Al4V alloy. For the edge force coefficients, it is observed a slight variation when using cutting tools with different helix angles. Besides, the cutting force amplitudes strongly depend upon the workpiece material. The helix angle has a significant influence on the transverse force amplitude at conventional speed. The forces obtained mechanistically are also substantiated by comparison with measurements.

A Hybrid Cutting Force Model for High-speed Milling of Titanium Alloys

CIRP Annals ◽  
2005 ◽  
Vol 54 (1) ◽  
pp. 71-74 ◽  
Author(s):  
Z.G. Wang ◽  
M. Rahman ◽  
Y.S. Wong ◽  
X.P. Li
Keyword(s):  
Titanium Alloys ◽  
Cutting Force ◽  
High Speed ◽  
Force Model ◽  
Cutting Force Model ◽  
High Speed Milling

Instantaneous Cutting Force Model in High-Speed Milling Process with Gyroscopic Effect

2011 ◽  
Vol 314-316 ◽  
pp. 389-392
Author(s):  
Hong Liang Zhou ◽  
Wei Xiao Tang ◽  
Qing Hua Song ◽  
Hua Wei Ju
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
End Milling ◽  
Element Model ◽  
Face Milling ◽  
Force Model ◽  
Dynamics Model ◽  
Cutting Force Model ◽  
Gyroscopic Effect ◽  
High Speed Milling

High-speed milling (HSM) has advantages in high productivity high precision and low production cost. Thus it can be widely used in the manufacture industry. However, when the speed of spindle-tool reaches a higher speed range, the gyroscopic effect will become an important part of its stable milling. In this paper, a dynamics model of HSM system was proposed considering the influence of gyroscopic moment due to high rotating speed of end milling. Finite element model (FEM) is used to model the dynamics of a spindle-milling system. It obtains the trajectory of central point in face milling with considering gyroscopic effects through the dynamics model at high speeds. Then the cutting force model will be corrected by the trajectory of face milling. So it can provide a basis for stability prediction of high speed milling.

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