An Improved Model of the Chip Thickness in Milling

Śpiewak, S.

doi:10.1016/s0007-8506(07)62271-9

Cited by 44 publications

(22 citation statements)

References 7 publications

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“…Tool runout (radial and axial), uneven tooth positions, deformations and tool wear are characteristics affecting milling operations [1]. Among these characteristics, radial tool runout in end milling has received special attention from researchers, starting with the work published by Kline and DeVor [2], which focused on the effects of radial tool runout on cutting forces in end milling.…”

Section: Introductionmentioning

confidence: 99%

Dynamic analysis of runout correction in milling

Diez

Garcia

Villaseñor

et al. 2010

International Journal of Machine Tools and Manufacture

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Keywords:Milling Tool runout Cutting force control Piezoelectric actuator Tool runout and its effects is an important area of research within modelling, simulation, and control of milling forces. Tool runout causes tool cutting edges to experience uneven forces during milling. This fact also affects tool life and deteriorates workpiece surface quality. In this article a procedure, in order to diminish the effects of tool runout, is presented. The procedure is based on chip thickness modification by means of the fast correction of the tool feed rate. Dynamic feed rate modification is provided by superposing our own design of a fast feed system driven by a piezoelectric actuator to the conventional feed drive of the CNC machine tool. Previously, a model of the dynamic behaviour of the system was developed to analyze the influence of fast feed rate modification on cutting forces. The model incorporates the piezoelectric actuator response as well as the structural dynamics of the tool and the designed Fast Feed Drive System (FFDS). Simulated and experimental results presented in this paper show the effectiveness and benefits of this new tool runout correction procedure.

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Section: Introductionmentioning

confidence: 99%

Dynamic analysis of runout correction in milling

Diez

Garcia

Villaseñor

et al. 2010

International Journal of Machine Tools and Manufacture

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“…Figure 4 shows the model to obtain the machining dynamics. The dynamics of the milling system can be described by differential equations as follows: (13) where m aw , c aw , k aw , m ac , c ac , k ac (a = x, y) represent the modal mass, modal damping, and modal stiffness of the workpiece-holder system and the cutter-spindle system in the X and Y directions, which can be acquired by the aid of specific modal tests. F x (t) and F y (t) are the cutting forces in the X and Y directions.…”

Section: Dynamic Displacements Of Cutter and Workpiecementioning

confidence: 99%

“…This is a widely used static chip thickness model, but the chip thickness model fails to satisfy the increasing demands of accurate milling process model. Spiewak [13] took advantage of systematic modeling methodology to acquire the static chip thickness by employing homogeneous transformation technique and matrix formulation of the cutter geometry. Li et al [14] gave an improved method to approximate the static chip thickness instead of solving the unduly cumbersome transcendental equation concerned.…”

Section: Introductionmentioning

confidence: 99%

Improved method to predict cutting force in end milling considering cutting process dynamics

Zhao

Wang

et al. 2015

Int J Adv Manuf Technol

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Accurate cutting force prediction in end milling plays an important role in studying the characteristics of milling to improve the machining quality and optimize the machining processes. To this end, a new method that improves cutting force prediction accuracy by considering cutting process dynamics and simplifies the process of computing the dynamic chip thickness is presented in this paper. The static chip thickness is calculated and the cutting process dynamics is taken into account in this method. To ensure the result accuracy and improve computing efficiency, Taylor's series is adopted to acquire static chip thickness. Meanwhile, as feedback, the dynamic chip thickness caused by the cutter-workpiece system subjected to the cutting force is superposed on static chip thickness to get more accurate cutting force. Finally, the proposed method by dint of closed-loop system to acquire more accurate cutting force is experimentally validated in milling of plastic die steel NAK80 with a four fluted flat-end milling cutter. Cutting force coefficients and modal parameters are identified based on the experiment. Both the simulations with and without considering dynamics show good agreement with

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“…1 and 2, the velocity components depend on the insert orientation angles and on the angular position θ of the tool. Both rotation movement and feed speed generate a variation of the instantaneous feed h m [10][11][12]. This variation affects the primary shear zone length l (4) and thus the strain and strain rate cartography.…”

Section: Kinematic Studymentioning

confidence: 99%

3D modeling of strain fields and strain rate in the cutting area: application to milling

Yousfi

Darnis

Cahuc

et al. 2015

Int J Adv Manuf Technol

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Given the complexity of the physical phenomena present in machining, orthogonal cutting is the configuration that has been most studied and modeled analytically. However, this configuration is no longer applicable if we consider the true orientations of the cutting edge found in the modeling space, for , during milling. Along the cutting edge, geometric and kinematic parameters vary considerably and the speed vector at each point is very sensitive to the true position of the point under consideration on the cutting edge. For each shear zone, the study proposed here looks at the effect of velocity gradients on the strain and strain rate fields. These velocity gradients generate extra chip displacement, in three dimensions, and consequently give rise to new force components and cutting moments. This study describes the overall calculation process, starting with a detailed description of each characteristic zone in the cutting area. By determining the speed vector and the displacement vector, strains and strain rates can be mapped for the entire volume of the cutting area when milling.

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An Improved Model of the Chip Thickness in Milling

Cited by 44 publications

References 7 publications

Dynamic analysis of runout correction in milling

Dynamic analysis of runout correction in milling

Improved method to predict cutting force in end milling considering cutting process dynamics

3D modeling of strain fields and strain rate in the cutting area: application to milling

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