Cutting force prediction and analytical solution of regenerative chatter stability for helical milling operation

Modeling and analyses of helical milling process

“…Denkena et al [17] modeled the undeformed chip geometry for helical milling in which the axial depth of cut of periphery cutting edges is assumed to increase approximately linearly with the tool rotation angle, and used it to explain the impact of the axial and tangential feed per tooth on the process forces. Li et al [18] described the cutting depths and undeformed chip geometry of conventional end mill, then proposed a novel dynamic cutting force model for helical milling. Chen et al [19] presented a new dynamic cutting force model with nominal chip thickness for predicting the stability of interrupted turning, in where the dynamical cutting force was defined by a function of nominal chip thickness and dynamical chip thickness.…”

3D FEM simulation of helical milling hole process for titanium alloy Ti-6Al-4V

“…Li et al [14] established a three-dimensions (3D) surface topography simulation model base on an improved Z-map model to simulate the surface finish profile generated after a helical milling operation. A novel dynamic cutting force model is also proposed for helical milling process on the basis of a quantitative description of cutting zones corresponding to helical milling operation, in which the cutting mechanism and the cutting force contribution on both the peripheral and the front cutting edges are taken into consideration simultaneously [15]. Liu et al [16] proposed an cutting force model to predict the cutting force and torque in a helical milling operation as a function of spindle speed, helical feed, radial and axial cutting depth and cutter geometry.…”

Effect of Nominal Chip Thickness on Stability of Interrupted Turning

“…A unified geometric, kinematic, and mechanic model was proposed which allows the prediction of chatter stability for multiple machining operations with defined cutting edges by Altintas et al [11,12]. A novel dynamic cutting force model is proposed by Li et al [13], in which the cutting mechanism and the cutting force contribution on both the peripheral and the front cutting edges are taken into consideration simultaneously. An interrupted turning cutting force model was proposed and a detailed analysis of the stability was performed by Seguy et al [14].…”

“…An interrupted turning cutting force model was proposed and a detailed analysis of the stability was performed by Seguy et al [14]. In the above studies [1][2][3][4][5][6][7][8][9][10][11][12][13][14], the cutting force models are linear, without considering nonlinearities in terms of chip thickness. Given this, powerlaw function for cutting force was used to analyse chatter by Hanna and Tobias [15] and Stépán et al [16] and Yang et al [17].…”

“…It is worth noting that, in the above studies [1][2][3][4][5][6][7][8][9][10][11][12][13][14][15][16][17][18][19], dynamic cutting forces are only the function of dynamic chip thickness, and cutting force versus unit of dynamic chip thickness must be unique. However as shown in Figure 1, cutting forces versus the same dynamic chip thickness (Δℎ 1 = Δℎ 2 ) are unequal at different nominal chip thickness (Δ 1 ̸ = Δ 2 ), due to the fact that the nominal chip thickness is neglected.…”