Minimizing time of contour-parallel pocket end-milling by prescribing limit axial and radial depth pairs

Godwin, Ozoegwu Chigbogu

doi:10.1177/0954405416673099

Cited by 5 publications

(2 citation statements)

References 27 publications

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“…Wu [27] optimized the milling parameters by changing the cutter center coordinates and analyzing the geometric contact relationship of cutting with constant cutting force as the goal. Godwin [28] took the minimum pocket processing time as the goal, and considered the axial and radial cutting depths to achieve efficient pocket processing.…”

Section: Introductionmentioning

confidence: 99%

Corner milling force prediction and improvement method of aviation thin-walled structural parts

Chen

Yue

Liu

et al. 2023

Int J Adv Manuf Technol

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Corner is one of the typical characteristics of aerospace monolithic components. In order to achieve a stable processing environment and reduce the mutation of milling force in the process of machining, the manufacturer has been searching a method to control the milling force of corner machining. Based on the cutting contact relationship and the instantaneous chip thickness, the milling force prediction model of corner machining is established. By analyzing different types of corner contact relationship, the influence of cutting contact angle and cutting arc length on milling force is established. The corner feed rate iterative calculation method is used to improve the corner milling force mutation. The corner milling experiment proves that the proposed method can not only effectively control the corner milling force, but also improve the surface quality of the bottom surface of the workpiece. The proposed method is suitable for automatic programming of multi-corner pocket machining and provides theoretical support for stable machining of frame part.

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Section: Introductionmentioning

confidence: 99%

Corner milling force prediction and improvement method of aviation thin-walled structural parts

Chen

Yue

Liu

et al. 2023

Int J Adv Manuf Technol

View full text Add to dashboard Cite

show abstract

“…It influences other performance indicators like chatter, cutting energy, heat generation and distribution, dimensional accuracy/quality and machining economics. 1,2 As a result, accurate measurement and modeling of cutting forces has been a major research focus in the manufacturing field. Measurable cutting forces are usually integrated from force distributions or pressures on the cutting edges.…”

Section: Introductionmentioning

confidence: 99%

Closed-form models for the cutting forces of general-helix cylindrical milling tools

Ozoegwu

Eberhard

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Cutting force is the predictor of the performance indicators of machining processes, therefore, the measurement and modeling accuracy have received sustained research attention. The existing closed-form models for milling cutting force are useful for an analytical design process and optimization (over large parametric ranges) but the methods are not applicable to milling tools with arbitrary helix angle variation (general-helix). On the other hand, numerical methods are available for general-helix tools but are only applicable in an analytical design process and optimization when they are used to create surrogate models. The aim of this work is to develop closed-form models that retain the benefits of both approaches for computing the cutting forces of general-helix cylindrical milling tools by combining the properties of the analytical and numerical approaches. The proposed closed-form modeling approach is shown to be more accurate and more convergent than the numerical approach and checked using published experimental data for a fixed helix angle milling tool. For this illustrative case, the percentage error of a proposed closed-form model for the unsegmented (1-segment) tool model relative to the 500-segment model (considered exact) is 0.00% when the error for the equivalent numerical method is 1.90%. Higher accurate applicability of the proposed closed-form models to variable helix tools is also demonstrated for the harmonic case. The percentage error of a proposed closed-form model for the 1-segment tool model relative to the 500-segment model (considered exact) is 0.28% when the error of the equivalent numerical method is 1.05% for this illustrative case. The advantage in terms of generalized applicability and the disadvantage in terms of minor discretization error are highlighted against the backdrop of an existing close-form model for fixed helix angle tools.

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Geometric definition, rapid prototyping, and cutting force analysis of cylindrical milling tools with arbitrary helix angle variations

Ozoegwu

Eberhard

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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In this work, a method is developed for geometric definition and analysis of cylindrical milling tools having various free-form variations of helix angle. The method is based on replicating a position vector on each cutting edge to generate a point set for the whole tool envelope using piece-wise rotation and magnification matrices which are varied according to mathematical laws describing the intended variable shape of the tool. The computed point sets are applied in additive manufacturing of samples of such tools having non-conventional shape features by transforming the point sets to stereolithography formats that are sliced to guide the 3D-printing processes. This manufacturing route that simplifies the realization of arbitrary helix profiles on milling tools is a major contribution of this work since such tools are gaining popularity for their passive damping of vibrations and reduction of cutting forces but are notoriously difficult to manufacture, limiting their exploitation. Analyses are shown about the effects of the considered variable profiles on milling cutting force. These suggest that cutting forces can be greatly suppressed by the proposed free-form helix angle variations. For example, relative to a conventional fixed helix tool of same mean helix angle, the innovative tools recorded 40.33%–84.42% and 60.53%–67.81% force reductions at axial depths of cut of 1 and 5 mm. This demonstrates that innovative variable tool profiles which can be realized through the simplified rapid prototyping technique are promising for advanced sustainable manufacturing of parts with preferred surface conditions.

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Minimizing time of contour-parallel pocket end-milling by prescribing limit axial and radial depth pairs

Cited by 5 publications

References 27 publications

Corner milling force prediction and improvement method of aviation thin-walled structural parts

Corner milling force prediction and improvement method of aviation thin-walled structural parts

Closed-form models for the cutting forces of general-helix cylindrical milling tools

Geometric definition, rapid prototyping, and cutting force analysis of cylindrical milling tools with arbitrary helix angle variations

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