Modeling of cutting geometry and forces for 5-axis sculptured surface machining

Fussell, Barry K.; Jerard, Robert B.; Hemmett, Jeffrey G.

doi:10.1016/s0010-4485(02)00055-6

Cited by 130 publications

(36 citation statements)

References 16 publications

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“…The uncut chip thickness t c , i.e., the thickness of the material removed by a flute, at any location on the cutter, can be determined using Eq. (1), where f t is the feed per tooth vector and n s is the unit normal vector of cutter surface at the angular position θ and axial height z [21,22]. The element cutting forces on a tooth are computed from the chip area and specific cutting energy, which also changes with the uncut chip thickness.…”

Section: Cutting Force Model and Experimentsmentioning

confidence: 99%

“…The element cutting forces on a tooth are computed from the chip area and specific cutting energy, which also changes with the uncut chip thickness. The relationship between a specific cutting energy and uncut chip thickness, as proposed by Sabberwal, is used to consider the size effect [21][22][23][24][25][26]. The specific cutting energy is a function of the uncut chip thickness and empirical constants K c and p, which are dependent on the tool and material.…”

Section: Cutting Force Model and Experimentsmentioning

confidence: 99%

“…The instantaneous cutting force F c is computed by adding the element cutting forces of tooth N along the axial depth of the cut d a , as shown in Eq. (3) [21][22][23][24][25].…”

Section: Cutting Force Model and Experimentsmentioning

confidence: 99%

“…Instantaneous cutting forces and average powers are computed from the specific cutting energy and intersection of tool and workpiece [17][18][19][20][21][22][23][24]. The active feed rate is inserted in NC data to reduce machining time while the instantaneous maximum cutting force is below the limit.…”

Section: Introductionmentioning

confidence: 99%

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Integration of Pre-Simulation and Sensorless Monitoring for Smart Mould Machining

Kim¹

2016

Int. j. simul. model.

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A smart mould machining system, which detects machining status and controls the CNC through presimulation and real-time data, was developed. Pre-simulation predicts cutting forces, and inserts the best feed rate and virtual load on each line of the NC data. The active feed rate reduced machining by up to 36 %, without increasing the maximum cutting forces. The actual cutting load was computed from spindle load data and a friction load compensation algorithm. Collision and tool wear were detected by comparing the actual and virtual load, with the time synchronised by using tool position data. The system machined an automotive grill mould cavity for 34 hours without the supervision of a worker, because pre-simulation had stabilized the milling process and monitoring would have stopped the process if the actual load was different to the virtual load. Pre-simulation has been verified by thousands of mould makers and integrated with sensorless monitoring in an open CNC.

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Section: Cutting Force Model and Experimentsmentioning

confidence: 99%

Section: Cutting Force Model and Experimentsmentioning

confidence: 99%

“…The instantaneous cutting force F c is computed by adding the element cutting forces of tooth N along the axial depth of the cut d a , as shown in Eq. (3) [21][22][23][24][25].…”

Section: Cutting Force Model and Experimentsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Integration of Pre-Simulation and Sensorless Monitoring for Smart Mould Machining

Kim¹

2016

Int. j. simul. model.

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“…The undeformed chip thickness was determined in the cutter surface normal direction. This direction was later adopted by several other researchers [11][12][13][14][15]. In contrast, Feng and Menq [16] formulated their mechanistic cutting force model for ball-end milling by defining the undeformed chip thickness as the radial distance between two consecutive cutting edge trajectories in the horizontal direction.…”

Section: Introductionmentioning

confidence: 99%

Cutting force prediction for ball-end mills with non-horizontal and rotational cutting motions

Azeem

Feng

2012

Int J Adv Manuf Technol

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Accurate cutting force prediction is essential to precision machining operations as cutting force is a process variable that directly relates to machining quality and efficiency. This paper presents an improved mechanistic cutting force model for multi-axis ball-end milling. Multi-axis ballend milling is mainly used for sculptured surface machining where non-horizontal (upward and downward) and rotational cutting tool motions are common. Unlike the existing research studies, the present work attempts to explicitly consider the effect of the 3D cutting motions of the ballend mill on the cutting forces. The main feature of the present work is thus the proposed generalized concept of characterizing the undeformed chip thickness for 3D cutter movements. The proposed concept evaluates the undeformed chip thickness of an engaged cutting element in the principal normal direction of its 3D trochoidal trajectory. This concept is unique and it leads to the first cutting force model that specifically applies to non-horizontal and rotational cutting tool motions. The resulting cutting force model has been validated experimentally with extensive verification test cuts consisting of horizontal, non-horizontal, and rotational cutting motions of a ball-end mill.

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Bibliography

2016

Milling Simulation

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Modeling of cutting geometry and forces for 5-axis sculptured surface machining

Cited by 130 publications

References 16 publications

Integration of Pre-Simulation and Sensorless Monitoring for Smart Mould Machining

Integration of Pre-Simulation and Sensorless Monitoring for Smart Mould Machining

Cutting force prediction for ball-end mills with non-horizontal and rotational cutting motions

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