Mechanistic identification of specific force coefficients for a general end mill

Gradišek, Janez; Kalveram, Martin; Weinert, Klaus

doi:10.1016/j.ijmachtools.2003.10.001

Cited by 227 publications

(94 citation statements)

References 10 publications

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“…Janez G [14] proposed a method of cutting and edge force coefficients identification based on average edge forces related to cutter geometry and engagement of cutter and the work piece. For a cutter with given geometry, the cutting and edge coefficients in Equation (6) are obtained by equating the measured cutting forces with the corresponding analytical expressions.…”

Section: Milling Force Coefficients Identificationmentioning

confidence: 99%

Analytical Calculation of Cutting Forces in Ball-End Milling with Inclination Angle

Nan

Liu

2018

JMMP

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Abstract:The traditional analytical cutting force prediction method for ball-end milling ignores the effect of the inclination angle on cutting forces. In this paper, a new experimental method for cutting force prediction methods considering the inclination angle in the ball-end milling process is proposed. First, the actual immersion ranges of cutter in the ball-end milling process with and without an inclination angle are analyzed by a geometrical method and the cutting force prediction model with an inclination angle is developed by a numerical integration method. Second, considering that entry and exit angles of cutting zones for different cutter layers vary due to the inclination angle, a milling force coefficients identification approach for different cutter layers is established by experimental calibration. Comparing the traditional analytical cutting force prediction method that ignores the inclination angle, the numerical simulation results show that the prediction force values calculated by the proposed method have a better consistency with the measured values.

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Section: Milling Force Coefficients Identificationmentioning

confidence: 99%

Analytical Calculation of Cutting Forces in Ball-End Milling with Inclination Angle

Nan

Liu

2018

JMMP

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“…Engin and Altintas studied the geometry of a generalized mathematical model wrapped by helical flutes around a parametric envelope [11], and cutting forces were then predicted by integrating the process along each cutting edge. Gradisek and other researchers developed expressions for semimechanistic identification of shearing and edge force coefficients including helix angle in the evaluation of average edge force [12]. Besides, a simplified and efficient calibration method to estimate the force coefficients for ball-end milling was proposed [13].…”

Section: Advances In Mechanical Engineeringmentioning

confidence: 99%

“…Cutting forces at any rotational moment acting on the th cutting edge can be get by integrating (12) along the axial cutting depth…”

Section: Thementioning

confidence: 99%

Prediction and Experimental Validation of Cutting Force for Bull-Nose End Mills with Lead Angle

Gao

Luo

et al. 2014

Advances in Mechanical Engineering

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This study focuses on cutting force predictions with the tool-workpiece inclination angle in bull-nose milling based on the semimechanistic force model. By analyzing kinematics and mechanics of the bull-nose end mills during cutting, force expressions including lead angle are stated and the model is exerted on each discrete element as oblique cutting with coordinate transformation and numerical integration to obtain the dynamic cutting force components. An improved identification method considering speed variations along the tool axis is applied to calibrate coefficients. Coefficients are regarded as the function of each elemental elevation. Then, a geometry-based method to acquire cutter workpiece engagement (CWE) is proposed. Also acquisition of accurate start and exit angles on each slice is deliberated elaborately for cutters with lead or tilt angle in milling processes. Thereby, to verify the validity of the force prediction model and start-exit angle acquisition method, experiments with variable lead angles are conducted under different axial immersions. The results reveal that the presented model and approaches can predict cutting forces with high accuracy. Finally, the cutting force components under different cutter postures and conditions are analyzed to provide instructions for parameter selections.

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“…The mechanistic models are commonly available to predict cutting forces, in which the cutting coefficients are calibrated using the empirical curve fit from a set of milling experiments [4][5][6][7][8] or orthogonal/oblique cutting data [9][10][11][12] for a given tool-workpiece pair. Despite the increased sophistication and usefulness of the developed mechanistic models for studying the cutter deflection and runout, surface errors, chatter vibrations, and federate optimization [13][14][15][16], the models are only valid for a certain workpiece-tool material pair and the cutting coefficients calibration done by numerous experiments is fastidious due to high cost and hardware setup complexity.…”

Section: Introductionmentioning

confidence: 99%

An analytical force model for ball-end milling based on a predictive machining theory considering cutter runout

Yang

Wang

et al. 2015

Int J Adv Manuf Technol

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The work is motivated by the fact that cutting forces are commonly calculated by the mechanistic or numerical models which are considered time-consuming and impractical for various cutting conditions and workpiece-tool pair, and the irregular distribution of cutting forces is generated due to the uneven redistribution of the instantaneous uncut chip thickness (IUCT) caused by the cutter runout in ball-end milling process. Therefore, this paper presents an analytical force model considering the cutter runout for ball-end milling based on a predictive machining theory, which regards the workpiece material properties, tool geometry, cutting conditions, and types of milling as the input data. In this model, the shear flow stress is estimated by introducing a modified Johnson-Cook constitutive law which considers the phenomenon of the work hardening, temperature softening, and material size-effect. Each cutting edge of the ball-end cutter is discretized into a series of infinitesimal elements along the cutter axis and the cutting action of which is equivalent to the classical oblique cutting process. Thus, the cutting force components applied on each element can be calculated using a predictive oblique cutting model and the total instantaneous cutting forces are obtained by summing up the forces contributed by all cutting edges. What is more, this model takes into account the effect of the edge radius, varying sliding friction coefficient and cutter runout on the cutting forces. Finally, the proposed analytical model of cutting forces is verified by the published results and experimental data. Good agreement shows the effectiveness of the proposed analytical model and highlights the importance of the cutter runout on the forces.

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Mechanistic identification of specific force coefficients for a general end mill

Cited by 227 publications

References 10 publications

Analytical Calculation of Cutting Forces in Ball-End Milling with Inclination Angle

Analytical Calculation of Cutting Forces in Ball-End Milling with Inclination Angle

Prediction and Experimental Validation of Cutting Force for Bull-Nose End Mills with Lead Angle

An analytical force model for ball-end milling based on a predictive machining theory considering cutter runout

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