A new cutting force prediction method in ball-end milling based on material properties for difficult-to-machine materials

Zhang, Jia; Ge, Jie; Ma, Jian-wei; Gao, Yuanyuan; Liu, Zhen

doi:10.1007/s00170-016-8351-8

Cited by 14 publications

(7 citation statements)

References 30 publications

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“…where F xs , F ys and F zs are shear forces, F xe , F ye and F ze are edge forces in tangential, radial, and axial directions respectively. The cutting force coefficients can be obtained from equation (22) using inverse matrix transformation 16 :…”

Section: Determination Of Force Coefficientsmentioning

confidence: 99%

“…Various works have been reported to obtain the CWE region for the precise modeling to obtain the cutting forces. Jia et al 22 used work material strength, thermal conductivity, and plasticity to evaluate the force coefficients using the linear mechanistic model and the CWE region was obtained by Z-map. Huang et al 23 incorporated the local helix angle and derived cutter-workpiece contact area to predict forces in BPM.…”

Section: Introductionmentioning

confidence: 99%

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Determination of force coefficient based on instantaneous forces and linear mechanistic model in ball end milling

Dikshit

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Due to the intricate geometry, force prediction in the ball end milling process (BMP) is a challenging task. Cutting forces generated during BMP have an impact on important aspects of machining characteristics such as form error, chatter and vibration, surface finish, tool wear, and dimensional accuracy. These machining problems might be resolved by foreknowledge of the cutting forces. In the present research, a new and quick mathematical model based on the linear mechanistic method is reported to determine the force coefficients. The cutter’s hemispherical part is discretized into five discs along the axis at 0.4 mm uniform spacing in the range of 0.2–1.8 mm. For one cutter revolution, forces in the tangential, radial, and axial directions are measured for each disc to prevent radial runout. The current disc makes use of the preceding disc’s cutting force. To derive the shear and edge force coefficients, these are further divided into edge and shear forces. Validation experiments have been conducted and compared with the simulated forces to assess the predictive power of the developed force coefficient model. The predicted results are found to be remarkably close to the experimental results with an error of 5.5%, −8.6%, and 8.9% at 6631 rpm and 2.8%, −4.4%, and 2.21% at 10,052 rpm in tangential, radial, and axial forces, respectively.

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Section: Determination Of Force Coefficientsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Determination of force coefficient based on instantaneous forces and linear mechanistic model in ball end milling

Dikshit

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…In the research [25], a model of cutting forces for 5-axis ball-end milling of sculptured surfaces has been presented. Jia et al [26] introduced the material properties of the workpiece into a model for predicting cutting forces. In the study [27], the Deform 3D finite element analysis software was used to simulate the ball-end milling and to analyse the distribution patterns of milling forces.…”

Section: Introductionmentioning

confidence: 99%

An ANFIS-Mechanistic Simulator of Tool Loads in Ball-End Milling of Layered Metal Materials

Zuperl¹,

Kovacic²,

Brezocnik³

2022

Int. j. simul. model.

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This article presents a universal simulator of instantaneous loads on the cutting edges of ball-end mills for the processing of layered metal materials. The ANFIS-mechanistic simulator of cutting edge loads is designed for all typical geometries of ball-end mills and for layered materials with different machinability of individual layers. Two ANFIS (Adaptive Neuro Fuzzy Inference System) models are included in the simulator, which, based on the instantaneous radial thickness of the chip and the geometry of the spherical part of the ball-end mill, predict the material coefficients for the material layers. Comparison of the predicted tool loads with experimental data shows that the simulator accurately predicts the direction and magnitude of the instantaneous loads of the ball-end mill cutting edges when milling 3-layer metal material with different machinability of individual layers. The largest observed deviation of simulated load magnitudes for all verification machining tests is 21.7 %.

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“…4 Cutting state in different times:(a) entry zone; (b) exit zoneWhole cutting state in Fig.4shows that spherical cutting edges participate in and out of the cutting process gradually, the direct reflection is the cutting forces increase gradually. For pure horizontal feed, the contribution of points near the tool tip to chip thickness generation is almost negligible; however for pure vertical feed, the contribution from those points is significant[14]. In order to obtain a steady cut while plunging with a ball end mill, ball part of the tool has to engage with the workpiece from tool tip to ball cylindrical part transition level, once entire ball part engages with the workpiece, engagement conditions do not change in the following feed movements of the cutter, and cylindrical part does not contribute to cutting.…”

mentioning

confidence: 99%

“…Yucesan [12] and Altintas [13] carried out an in-depth analysis of the mechanical dynamics of the milling process performed by ball-end cutters, analyzed the change of cutting force in the time domain, considered the instantaneous regenerated chip load and force coefficients, and established cutting force model. Jia et al [14] introduced interaction between material properties and machining conditions, presented a novel ball-end milling force prediction model.…”

mentioning

confidence: 99%

Modeling and estimation of cutting forces in ball helical milling process

Wang

Tao

Jin

2021

Int J Adv Manuf Technol

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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.

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A new cutting force prediction method in ball-end milling based on material properties for difficult-to-machine materials

Cited by 14 publications

References 30 publications

Determination of force coefficient based on instantaneous forces and linear mechanistic model in ball end milling

Determination of force coefficient based on instantaneous forces and linear mechanistic model in ball end milling

An ANFIS-Mechanistic Simulator of Tool Loads in Ball-End Milling of Layered Metal Materials

Modeling and estimation of cutting forces in ball helical milling process

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