Analytical models for high performance milling. Part I: Cutting forces, structural deformations and tolerance integrity

Budak, Erhan

doi:10.1016/j.ijmachtools.2005.09.009

Cited by 210 publications

(90 citation statements)

References 17 publications

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“…It is noticed that the shape and values for the cutting force components F x and F y are similar to those of the cutter with three teeth. Also, these levels for the cutting forces, for a four flutes, seems to be typical for peripheral milling as this result is approximately close to the experimental ones found by Budak (2006a). The percentage ratio of the difference between the absolute maximum predicted and measured value relative to the measured value represents an error of 9%.…”

Section: Resultssupporting

confidence: 86%

Cutting parameters and vibrations analysis of magnetic bearing spindle in milling process

Bouaziz¹,

Barkallah²,

Bouaziz³

et al. 2016

jtam

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In modern production, milling is considered the widespread cutting process in the formatting field. It remains important to study this manufacturing process as it can be subject to some parasitic phenomena that can degrade surface roughness of the machined part, increase tool wear and reduce spindle life span. In fact, the best quality work piece is obtained with a suitable choice of parameters and cutting conditions. In another hand, the study of tool vibrations and the cutting force attitude is related to the study of bearings as they present an essential part in the spindle system. In this work, a modeling of a High Speed Milling (HSM) spindle supported by two pair of Active Magnetic Bearings (AMB) is presented. The spindle is modeled by Timoshenko beam finite elements where six degrees of freedom are taken into account. The rigid displacements are also introduced in the modeling. Gyroscopic and centrifugal terms are included in the general equation. The bearings reaction forces are modeled as linear functions of journal displacement and velocity in the bearing clearance. A cutting force model for peripheral milling is proposed to estimate the tool-tip dynamic responses as well as dynamic cutting forces which are also numerically investigated. The time history of response, orbit, FFT diagram at the tool-tip center and the bearings dynamic coefficients are plotted to analyze dynamic behavior of the spindle.

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Section: Resultssupporting

confidence: 86%

Cutting parameters and vibrations analysis of magnetic bearing spindle in milling process

Bouaziz¹,

Barkallah²,

Bouaziz³

et al. 2016

jtam

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show abstract

“…The different types of reinforcement ceramic particles are used to improve the mechanical properties of the aluminum alloys. Many researchers are preferred the Al 2 O 3 , B 4 C and SiC particles as reinforcement element for their superior mechanical properties. On the other hand, the implementations of MMCs are restricted in a very specific industry due to high fabrication cost and their poor machinability [1][2][3].…”

Section: Introductionmentioning

confidence: 99%

“…Milling operations are carried out to produce 3 dimensional complex shapes products for aerospace, automotive parts, mold and die at high quality using advanced high speed machining technologies. Despite the improving machining technologies, machining software, CNC, CAD/CAM and cutting tool performances, the milling operations are still limited due to the high cutting forces and machining stabilities [4]. The determination of optimum machining parameters, proper cutting tool material and geometry for ideal cutting forces must be considered to meet the increasing productivity demands and reliable machining.…”

Section: Introductionmentioning

confidence: 99%

Study on Machining Parameters for Thrust Force and Torque in Milling AA7039 Composites Reinforced with Al2O3/B4C/SiC Particles

Karabulut

2016

IJET

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Abstract-Metal matrix composites are used in many industrial fields such as automobile, military and aerospace applications due to their superior mechanical properties. In the present study, three aluminum 7039 metal matrix composite (MMCs) samples reinforced with 10 wt.% particulates of aluminum oxide (Al 2 O 3 ), 10 wt.% boron carbide (B 4 C), and 10 wt.% silicon carbide (SiC) were successfully fabricated using a powder metallurgy and hot extrusion method. The influences of cutting parameters on the thrust cutting force and torque during milling of the three MMCs were investigated under dry machining conditions. The milling tests were performed based on the Taguchi orthogonal -array design of experiments, for different machining parameters such as cutting speed, feed and depth of cut. The effect of reinforcement contents on cutting force and torque were specified by utilizing analysis of variance (ANOVA). Mathematical models have been generated for the thrust force and torque through regression method. The results indicated that the minimal thrust force and torque were obtained in the machining of the Al 2 O 3 reinforced specimen. The cutting force was directly influenced by the cutting feed and the axial cutting depth was the most effective machining parameter affecting milling torque in the machining of three composite specimens. The experimental results were modeled using regression analysis and artificial neural networks (ANN) to predict the thrust force and torque. The thrust force and torque were predicted with a mean squared error equal to 5.85% and 5.12% respectively using ANN models.

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“…Due to the advances in machine tool, computer numerical control (CNC), computer aided design/computer aided manufacturing (CAD/CAM), cutting tool, and high speed machining technologies in the last couple of decades, the volume and importance of milling have increased in key industries such as aerospace, die and mold, automotive and component manufacturing [1]. With the advances in cutting tool technologies, hard milling has been recently employed to machine hardened steels (> 30 HRC) in making dies and molds for various automotive and electronic components as well as plastic molding parts [2].…”

Section: Introductionmentioning

confidence: 99%

Genetic Evolutionary Approach for Cutting Forces Prediction in Hard Milling

Taylan

KAYACAN>

2011

Zeitschrift Für Naturforschung A

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Hard milling is a very common used machining procedure in the last years. Therefore the prediction of cutting forces is important. The paper deals with this prediction using genetic evolutionary programming (GEP) approach to set mathematical expression for out cutting forces. In this study, face milling was performed using DIN1.2842 (90MnCrV8) cold work tool steel, with a hardness of 61 HRC. Experimental parameters were selected using stability measurements and simulations. In the hard milling experiments, cutting force data in a total of three axes were collected. Feed direction (F x ) and tangential direction (F y ) cutting forces generated using genetic evolutionary programming were modelled. Cutting speed and feed rate values were treated as inputs in the models, and average cutting force values as output. Mathematical expressions were created to predict average F x and F y forces that can be generated in hard material milling.

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Analytical models for high performance milling. Part I: Cutting forces, structural deformations and tolerance integrity

Cited by 210 publications

References 17 publications

Cutting parameters and vibrations analysis of magnetic bearing spindle in milling process

Cutting parameters and vibrations analysis of magnetic bearing spindle in milling process

Study on Machining Parameters for Thrust Force and Torque in Milling AA7039 Composites Reinforced with Al2O3/B4C/SiC Particles

Genetic Evolutionary Approach for Cutting Forces Prediction in Hard Milling

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