Frequency-domain stability lobe prediction for high-speed face milling process under tool–workpiece dynamic interaction

Fast and accurate cutting force prediction is still one of the most complex problems and challenges in the machining research community. In this study, a modified finite element model is presented to predict cutting force and cutting length in turning operations of AISI 1018. Unlike the existing research, in which the mean friction coefficient μ was taken, a variable friction coefficient μ involving the sliding velocity between chip and tool is presented in this article. The sticking–sliding friction model is adopted, and the maximum limiting stress in sticking region is calculated by considering the thermal softening and normal stress distribution. Experiments have been performed for machining AISI 1018 using tungsten carbide tool, and simulation results have been compared to experiments. The simulation results of the modified finite element model have shown better outputs in predicting cutting force, tangential force, and tool–chip contact length on the rake face. The results of this article not only are meaningful to optimize tool design and cutting parameters but also can provide a clear understanding of contact behavior between tool rake face and chip.

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“…18,27,28 It is often difficult to obtain these frictional conditions, which depends on tool and work material pairs in metal cutting. 29–31…”

Section: Fem and Friction Evolutionmentioning

confidence: 99%

Cutting performance investigation based on the variable friction model by considering sliding velocity and limiting stress

Shi

Duan

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…In equation (12), d F tijk , d F rijk , and d F aijk are tangential, radial, and axial infinitesimal milling forces, respectively; N t is the number of milling cutter tooth; M is the total number of infinitesimals on the tooth along the axial direction; ∅ ijk is the immersion angle and ∅ ijk = ( π / 30 ) lndt + ( 2 π ( j − 1 ) ) / N t + k tan β / MR , where β is the helix angle of the cutter. 32,33…”

Section: Dynamic Model Of Peripheral Millingand the Numerical Solutionmentioning

confidence: 99%

Modelling and simulation of surface topography machined by peripheral milling considering tool radial runout and axial drift

Chen

Wang

2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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Based on the Z-map model of a workpiece and the dynamic cutting forces model of peripheral milling in which the regenerative effect of tool radial runout and axial drift are considered, a model for the prediction of surface topography in peripheral milling operations is presented. According to the stability lobe diagram obtained by the zero-order analytical method, the relationship between spindle speed and surface topography, the tool radial runout, and the axial drift following the chatter are studied. The results show that a stable cutting status but a poor surface finish is obtained at the spindle speeds at which the dominant frequency of the milling system is integral multiples of the selected machining frequency, and a stable cutting status with a good surface finish can be obtained near and on the left side of the resonant spindle speeds determined by the predicted stability lobe diagram. The motion equations of any tooth end mill for peripheral milling are established, and these equations are based on the transformation matrix and the vector operation principle of motion-homogeneous coordinates. In addition, the simulation algorithm and the system of surface topography generated in peripheral milling are given based on the Z-map model. Cutting tests are carried out, and good agreement between the measured surface topographies and the topographies predicted by the model in this study is found in terms of their shape, magnitude, feed mark, profile height of cross-section, and surface roughness. The simulation results show that the milling surface roughness increases with the increase in feed per tooth, which further shows that this simulation system has high credibility. Thus, the simulation and experimental results can provide some practical instructions for the actual peripheral milling in determining the optimal machining conditions.

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“…The subscript ''xy'' denotes that the response in the X direction is excited by the force in the Y direction. The second-order differential equations of q(t) is derived from equation (9) in the following general form…”

Section: Extended Dynamic Milling Model With Mode Coupling and Procesmentioning

confidence: 99%

“…Guo et al 8 studied SLD in milling with multi-delays considering helix angle effect. Shi et al 9 predicted SLD for face milling processes considering the dynamic interaction between cutting tool and workpiece. Schmitz and colleagues 10,11 revealed the effect of helix angle and run-out on SLE.…”

Section: Introductionmentioning

confidence: 99%

Chatter stability and surface location error predictions in milling with mode coupling and process damping

Jiang

Sun

2017

Proceedings of the Institution of Mechanical Engineers, Part B:

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Together with machining chatter, surface location error induced by forced vibration may also inhibit productivity and affect workpiece surface quality in milling process. Addressing these issues needs the combined consideration of stability lobes diagram and surface location error predictions. However, mode coupling and process damping are seldom taken into consideration. In this article, an extended dynamic milling model including mode coupling and process damping is first built based on classical 2-degree-of-freedom dynamic model with regeneration. Then, a second-order semi-discretization method is proposed to simultaneously predict the stability lobes diagram and surface location error by solving this extended dynamic model. The rate of convergence of the proposed method is also investigated. Finally, a series of experiments are conducted to verify the veracity of the extended dynamic model. The modal parameters including direct and cross terms are identified by impact experiments. Via experimental verification, the experimental results show a good correlation with the predicted stability lobes diagram and surface location error based on the extended dynamic model. Also, the effects of mode coupling and process damping are revealed. Mode coupling increases the whole stability region; however, process damping plays a vital role in stability improvement mainly at low spindle speeds.

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Frequency-domain stability lobe prediction for high-speed face milling process under tool–workpiece dynamic interaction

Cited by 10 publications

References 12 publications

Cutting performance investigation based on the variable friction model by considering sliding velocity and limiting stress

Cutting performance investigation based on the variable friction model by considering sliding velocity and limiting stress

Modelling and simulation of surface topography machined by peripheral milling considering tool radial runout and axial drift

Chatter stability and surface location error predictions in milling with mode coupling and process damping

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