Cutting forces are often used to optimize cutting parameters and analyze cutting characteristics of the tool. Accurate prediction of cutting forces is critical to understand deeply of the cutting process, especially for helical milling of the difficult-to-cut materials. Generally, the cutting force coefficients are not affected by the cutting parameters in the end milling process, but due to the special cutting mechanism of helical milling, the change of the cutting force coefficients must be carefully studied. However, the identification of cutting force coefficients is very important to simulate cutting forces accurately, and the relationship between cutting force coefficient and cutting parameters needs to be carefully considered. To analyze the change of cutting forces, this paper respectively proposes linear and nonlinear cutting force models applied for the helical milling process, then according to the helical milling experiments, cutting coefficients are identified using an inverse method through instantaneous force in the linear model, at the same time, the coefficients are identified by similar average force method in the nonlinear model, simulated three-direction cutting forces under two different situations are compared to the experimental results. The relationship between cutting force coefficients and cutting parameters is analyzed in detail, the linear and nonlinear models as well as the fitting relations of different cutting force coefficients are compared. The aim of this paper is to study the influence of cutting parameters on the cutting coefficients, thus create a model to predict reliably the cutting force with different cutting parameters. peripheral edge and frontal edge along the helical feed path through considering the tangential and axial motion of the cutter, and verified it using the helical milling experiment of titanium alloy. Rey et al. (2016) established a mechanical cutting force model related to the cutter geometry and cutting parameters and instantaneous chip thickness, so that the quality of hole-making can be improved by controlling the cutting force. Sadek et al. (2012) proposed a cutting force model based on fracture mechanics, and found that the main factors causing the outlet delamination of CFRP material were the axial load distribution. There are more and more researches on cutting force modeling in the helical milling process, and through the study of related literature, it can be known that the identification of cutting force coefficient is of the force coefficients in the linear and nonlinear model, complete the comparison of linear and nonlinear model precision, so as to create a model able to reliably predict the cutting force with different cutting parameters. ac
Milling forces play an important role in the milling process and are generally calculated by the mechanistic or numerical methods, reliable model of cutting force is very important for the simulation of milling process, which has big scientific significance to further improve machining quality. Ball helical milling technology is used to make holes based on the cutting principle of helical milling using ball end cutter, due to the influence of spherical surface machining characteristic, the modeling of cutting force in ball helical milling is difficult. Therefore, the main purpose of this paper is to first establish an analytical cutting force model in the ball helical milling process. Considering cutting characteristics in the axial feed, the kinematics of ball helical milling is first presented, then the chip thickness distribution in different directions along the cutting edges are predicted. Furthermore, based on the characteristics of helical milling technology and geometry shape of ball end mill and the classical mechanical cutting force model, through the study on the ball-end milling mechanics, a new relatively accurate theoretical cutting force model is established. At the same time, cutting force coefficients are identified through instantaneous force method according to the Ti-alloy experimental research result. Finally, higher simulation precision of cutting force model in ball helical milling process is received.
Milling forces play an important role in the milling process and are generally calculated by the mechanistic or numerical methods, reliable model of cutting force is very important for the simulation of milling process, which has big scientific significance to further improve machining quality. Ball helical milling technology is used to make holes based on the cutting principle of helical milling using ball end cutter, due to the influence of spherical surface machining characteristic, the modeling of cutting force in ball helical milling is difficult. Therefore, the main purpose of this paper is to first establish an analytical cutting force model in the ball helical milling process.Considering cutting characteristics in the axial feed, the kinematics of ball helical milling is first presented, then the chip thickness distribution in different directions along the cutting edges are predicted. Furthermore, based on the characteristics of helical milling technology and geometry shape of ball end mill and the classical mechanical cutting force model, through the study on the ball-end milling mechanics, a new relatively accurate theoretical cutting force model is established. At the same time, cutting force coefficients are identified through instantaneous force method according to the Ti-alloy experimental research result. Finally, higher simulation precision of cutting force model in ball helical milling process is received.
In the ball helical milling (BHM), when the ball end mill follows an orbital path around the center of the hole, it plunges into the workpiece material with a helical motion, and the movement of the tool is relatively complex. In order to deeply understand the material removal and cutting characteristics in the BHM process, kinematics of BHM technology is introduced first, then material removal is analyzed according to the shape and relative position relationship between the tool and the workpiece at different typical moments, material removal behavior is discussed through the cross-sectional area, and the cross-section features of the workpiece material. In addition, the change of cutting forces is analyzed through microelement force, and then entry and exit zones are discussed in detail. BHM experiments of titanium alloy were carried out; cutting forces were measured; and burrs around the hole and surface roughness of the hole are analyzed. The results show that the ball end mill can remove materials uniformly in the helical milling with stable cutting forces and high hole-making quality.
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