An identification model of cutting force coefficients for five-axis ball-end milling

Guo, Minglong; Wei, Zhaocheng; Wang, Minjie; Li, Shiquan; Liu, Shengxian

doi:10.1007/s00170-018-2451-6

Cited by 32 publications

(8 citation statements)

References 21 publications

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“…It confirms that the Johnson transformation has been done successfully [27]. In the lower right part of the figure shows the transformation formula, from which a cutting force model is built as shown in (5).…”

Section: Engineeringsupporting

confidence: 56%

“…The cutting force model is the basis for predicting cutting force during machining as well as the basis for selecting machining parameters to ensure cutting force has small value. Study on building cutting force model by theoretical method has been done by many authors, such as: when using face milling cutter [1,2], when using ball end milling [3][4][5], when using cylindrical end mill [6]. However, when building cutting force models according to these studies, the number of calculations is very large, and there is still a need for more experimental studies to determine some parameters, such as coefficient of friction and shear force coefficient.…”

Section: Introductionmentioning

confidence: 99%

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Study on model for cutting force when milling SCM440 steel

Thien

Trung

2021

Eureka: PE

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This article presents empirical study results when milling SCM440 steel. The cutting insert to be used was a TiN coated cutting insert with tool tip radius of 0.5 mm. Experimental process was carried out with 18 experiments according to Box-Behnken matrix, in which cutting speed, feed rate and cutting depth were selected as the input parameters of each experiment. In addition, cutting force was selected as the output parameter. Analysis of experimental results has determined the influence of the input parameters as well as the interaction between them on the output parameters. From the experimental results, a regression model showing the relationship between cutting force and input parameters was built. Box-Cox and Johnson data transformations were applied to construct two other models of cutting force. These three regression models were used to predict cutting force and compare with experimental results. Using parameters including coefficient of determination (R-Sq), adjusted coefficient of determination (R-Sq(adj)) and percentage mean absolute error (% MAE) between the results predicted by the models and the experimental results are the criteria to compare the accuracy of the cutting force models. The results have determined that the two models using two data transformations have higher accuracy than model not using two data transformations. A comparison of the model using the Box-Cox transformation and the model using the Johnson transformation was made with a t-test. The results confirmed that these two models have equal accuracy. Finally, the development direction for the next study is mentioned in this article

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Section: Engineeringsupporting

confidence: 56%

Section: Introductionmentioning

confidence: 99%

Study on model for cutting force when milling SCM440 steel

Thien

Trung

2021

Eureka: PE

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“…Wei et al [14] obtained the boundary curves of cutter workpiece engagement based on the surface intersection, and further solved the in cut cutting edge, but the method is complex. In this paper, based on the space limited method, a simpler analytical algorithm for in cut cutting edge is proposed, which does not depend on the known cutter workpiece engagement.…”

Section: In Cut Cutting Edgementioning

confidence: 99%

Force model of freeform surface multi-axis machining with fillet end mill based on analytical contact analysis

Guo

Wei

et al. 2021

Int J Adv Manuf Technol

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In the multi-axis machining of freeform surface, compared with ball end mill, the fillet end mill has higher machining efficiency under the same residual height and has been widely used. As the most important physical quantity in machining process, milling force has always been the focus of research. In this paper, the geometry contact between fillet end mill and freeform surface is analyzed by analytical method, and then the milling force prediction model of multi-axis machining is established. Based on differential discretization, the cutter location of multi-axis machining of freeform surface is approximate to multi-axis machining of oblique plane, which simplifies the research object. The inclination angle is defined to describe the relationship among cutter axis, feed and workpiece in cutter coordinate system. The space range of the cutting edge element participating in material cutting is constructed by the swept surface of previous tool path, the to-be machined surface and the feed direction surface, and the in cut cutting edge is determined by judging the cutting edge element one by one. Considering cutter run-out, the element cutting forces on the cylindrical and fillet surfaces of the fillet end mill are derived, and all the element forces within in cut cutting edge are summed by vector to obtain the overall milling force of fillet end mill. Simulation results show that, compared with the solid method, this contact analysis method between cutter and workpiece can take both efficiency and accuracy into account. In the machining experiment, the measured force and predicted force along tool path are consistent in trend and amplitude, which verifies the effectiveness of the milling force prediction model.

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“…The dynamics modeling of simple geometric workpieces is easy, such as the three-axis machining of a horizontal plane, an inclined plane, and a cylindrical surface [1][2][3] . Even if the inclined plane is machined by five axes, the analytical method can be used for modeling [4] . For the five-axis machining of a curved surface, the arbitrariness of the cutter axis and tool path increases the difficulty of dynamics modeling, which is mainly reflected in the contact solution between the workpiece and cutting edge.…”

Section: Introductionmentioning

confidence: 99%

A new dynamics analysis model for five-axis machining of curved surface based on dimension reduction and mapping

Guo

Wei

Wang

et al. 2022

Preprint

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The equipment used in various fields contain an increasing number of parts with curved surfaces of increasing size. Five-axis CNC (Computer Numerical Control) milling is the main parts machining method, while dynamics analysis has always been a research hotspot. The cutting conditions determined by the cutter axis, tool path, and workpiece geometry are complex and changeable, which has made dynamics research a major challenge. For this reason, this paper introduces the innovative idea of applying dimension reduction and mapping to the five-axis machining of curved surfaces, and proposes an efficient dynamics analysis model. To simplify the research object, the cutter position points along the tool path were discretized into inclined plane five-axis machining. The cutter dip angle and feed deflection angle were used to define the spatial position relationship in five-axis machining. These were then taken as the new base variables to construct an abstract two-dimensional space and establish the mapping relationship between the cutter position point and space point sets to further simplify the dimensions of the research object. Based on the in-cut cutting edge solved by the space limitation method, the dynamics of the inclined plane five-axis machining unit were studied, and the results were uniformly stored in the abstract space to produce a database. Finally, the prediction of the milling force and vibration state along the tool path became a data extraction process that significantly improved efficiency. Two experiments were also conducted which proved the accuracy and efficiency of the proposed dynamics analysis model. This study has great potential for the online synchronization of intelligent machining of large surfaces.

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An identification model of cutting force coefficients for five-axis ball-end milling

Cited by 32 publications

References 21 publications

Study on model for cutting force when milling SCM440 steel

Study on model for cutting force when milling SCM440 steel

Force model of freeform surface multi-axis machining with fillet end mill based on analytical contact analysis

A new dynamics analysis model for five-axis machining of curved surface based on dimension reduction and mapping

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