A modeling and prediction method for plunge cutting force considering the small displacement of cutting layer

Li, Junli; Yu, Weiwei; An, Qinglong; Chen, Ming

doi:10.1177/0954405420921739

Cited by 7 publications

(3 citation statements)

References 29 publications

(29 reference statements)

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“…Liang et al 11 proposed an original approach to schedule the feed-rate in open blisk multi-axis plunge milling, based on the material removal rate, to smooth the variance in cutting forces and torque. Li et al 12 established a plunge milling force model based on the combination of analysis and a three-dimensional finite element method to obtain the modified cutting layer parameters and optimise the cutting force. Gao et al 13 established an instantaneous chip thickness model which considers the tool radial runout effect and a plunge milling force prediction model.…”

Section: Introductionmentioning

confidence: 99%

A study of interferential tool position correcting algorithms in 3D impeller variable-axis rough plunge milling

Dong

Wang

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Plunge milling has significantly improved the rough machining efficiency of 3D impeller channels. However, in conventional plunge milling cutter position planning, interferences occurring at the end of every cutter position due to the sudden increase of radial depth is inevitable. This can seriously compromise the service life of the machine tool and cutter, and also reduce the efficiency at the interferential phase. This study optimised the tool path cutter axis vector of conventional rough machining of 3D impeller variable-axis plunge milling, thus making the angle between the normal vector of workpiece surfaces at the cutter contact point, and the cutter-axis vector of the adjacent tool position, gradually increase from the outlet to inlet on a very small scale. Based on this, an iterative algorithm for the tool centre position and cutter safety height was obtained, thus making the hub allowance of the optimised tool path for plunge milling as small as possible without affecting subsequent machining by avoiding the interferential phenomenon. Finally, the proposed method was verified by relevant numerical examples.

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Section: Introductionmentioning

confidence: 99%

A study of interferential tool position correcting algorithms in 3D impeller variable-axis rough plunge milling

Dong

Wang

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…In addition, many studies have concentrated on modeling and predicting the cutting force during blade machining and allowed for error compensation to improve the accuracy of the milling process. 20,21 As there are still profile differences among batches of blades after milling, the consistency of blades geometry and machining allowance will be affected and the final array precise machining pass rate and efficiency will be reduced. The traditional solution of the factory is to observe the light transmission of the blade with a blade measuring template, and then group the blades according to the light transmission which stands for the processing allowance.…”

Section: Introductionmentioning

confidence: 99%

Research on blade grouping method for array machining

Xiao-dong

Zhang

2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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Blades are the core component of aero-engines. The complexity of aero-engine blades deformation after multi-axis milling causes poor consistency in batch blades. In turn, the poor consistency of blades affects the aerodynamic performance of an aero-engine. Hence it is critical to ensure the consistency of blades before precise machining. This article proposes a clustering-based blade grouping strategy aiming to improve the consistency of the same group of blades automatically and efficiently. First, the feature vector of the blade and the distance between two blade surfaces are defined. Then the K-medoids clustering algorithm is used to group the blades. According to the maximum allowable distance between the blade surfaces and the Ray-Turi index, the ideal number of clusters, that is the number of groups, is determined. Finally, the clustering center of each cluster is selected as the blade processing model of each group. The experiment for aero-engine blade grouping and machining was performed to demonstrate the effectiveness of the proposed method and the results show that it can improve the consistency of the blades in each group. The geometric contour differences of the blades in the group are not more than 0.02 mm, which can satisfy the requirements of the following precise array machining.

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“…The dynamic cutting force is affected by the machine tool, workpiece, tool, cutting parameters, and other factors. 5–15 Among them, the relationship between the dynamic cutting behavior is the key to unveil the dynamic cutting force variation. Different distribution of cutter teeth errors are inevitable in terms of manufacturing and installation.…”

Section: Introductionmentioning

confidence: 99%

Identification method for the dynamic cutting force variation of a high energy efficiency milling cutter

Fan

Jiang

Zhao

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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The dynamic cutting force of a high energy efficiency milling cutter is an important indicator for evaluating the stability of the cutting energy efficiency. The existing cutting force analysis focuses on the main characteristics and influencing factors of the cutting force variation in the cutting process, ignoring the influence of the variation of the cutting layer parameters with the cutter tooth error in different cutting stages, and the dynamic cutting force variation is uncertain. In this research, the analytical model of the instantaneous cutting volume of a milling cutter was developed in order to obtain the time-frequency characteristics of the instantaneous cutting volume with the cutter tooth error. According to the sudden changes of the cutting force and the milling vibration, the variations were studied in different cutting stages. The dynamic cutting behavior sequences such as the instantaneous cutting volume, milling vibration, and dynamic cutting force were constructed to characterize the mapping relationship between the dynamic cutting behavior of a milling cutter. Based on these approaches, the identification method for the dynamic cutting force variation of a high energy efficiency milling cutter was proposed. The effectiveness of the method was verified by the results of the milling experiment and the dynamic cutting behavior response analysis. The results showed that the proposed method could effectively identify the variation and its control variables for the dynamic cutting force in the cutting process, and the method could provide a scientific basis for constructing the dynamic cutting force model of a high energy efficiency milling cutter.

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A modeling and prediction method for plunge cutting force considering the small displacement of cutting layer

Cited by 7 publications

References 29 publications

A study of interferential tool position correcting algorithms in 3D impeller variable-axis rough plunge milling

A study of interferential tool position correcting algorithms in 3D impeller variable-axis rough plunge milling

Research on blade grouping method for array machining

Identification method for the dynamic cutting force variation of a high energy efficiency milling cutter

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