Numerical simulation and prediction of cutting forces in five-axis milling processes with cutter run-out

Sun, Yunwen; Guo, Qiang

doi:10.1016/j.ijmachtools.2011.07.003

Cited by 75 publications

(33 citation statements)

References 29 publications

Supporting

Mentioning

Contrasting

Unclassified

Order By: Relevance

“…However, as long as the analytical expressions for q i (ψ(β)), h'(β) and the boundaries of the cutting region, θ 1 (β), θ 1 (β) and β 1 , β 2 ,, can be obtained or their numerical values are available, Eqs. (16) and (17) can be evaluated using one of the two methods below.…”

Section: Calculating the Fourier Series Coefficientsmentioning

confidence: 99%

See 1 more Smart Citation

Fourier Analysis of Milling Force for General Helical Cutters via Spacetime Convolution, Part 1: Model Development

Cm¹,

Jj²

2015

J Appl Mech Eng

View full text Add to dashboard Cite

A space-time convolution approach to analyze the milling force for a general helical cutter is proposed. The single flute cutting force is firstly established through an integrated space-time convolution process. Subsequently, multi-flute milling forces are obtained through convolution integration in time domain (i.e., angular domain). In this convolution force model, convolution theorem does not apply directly and a modified convolution theorem is presented to find the Fourier coefficients of the total milling force for any analytically definable helical cutter. From the Fourier analysis, the magnitudes of higher order Fourier coefficients are shown to drop off quickly. Therefore, the capability to extract a small number of Fourier coefficients as characteristic values of milling forces is an important advantage of this convolution force model. Furthermore, this model provides a convenient means to calculate the Fourier coefficients of the milling forces if the profile of cutter/workpiece can not be analytically definable and only the discrete values of cutter/workpiece profile data are given from scanning. Also, the general effects of cutter geometry and cutting parameters on the spectra characteristics of the milling forces are extracted and discussed. Based on the spectra characteristics, the strategy of selecting cutters for rough and finish machining in slot milling is presented.

show abstract

Section: Calculating the Fourier Series Coefficientsmentioning

confidence: 99%

“…Wan et al [15] developed a numerical force model for general end mills including runout effect using lumped shearing cutting coefficients. Based on the motion analysis, Sun and Guo [16] proposed a numerical force model for general end mills considering runout effect to predict cutting force in five-axis milling process.…”

Section: Introductionmentioning

confidence: 99%

Fourier Analysis of Milling Force for General Helical Cutters via Spacetime Convolution, Part 1: Model Development

Cm¹,

Jj²

2015

J Appl Mech Eng

View full text Add to dashboard Cite

show abstract

“…3). Prowadzi to z kolei do zmiennego odkształcenia sprężystego narzędzia oraz przedmiotu obrabianego, czego skutkiem może być niedokładność wymiarowo -kształtowa [3,4,5,6]. Dokładność wykonania powierzchni opływowych łopatek turbin ma wpływ na trwałość i niezawodność całej turbiny.…”

Section: Rys 1 Rodzaje Powierzchni Złożonych O Promieniach Krzywiznunclassified

Effect of toroidal cutter axis orientation on the cutting forces in the five-axis machining of sculptured surface turbine blade of INCONEL 718

et al. 2015

View full text Add to dashboard Cite

StreszczeniePrzedstawiono wyniki badań składowych sił skrawania podczas procesu symultanicznego 5-osiowego frezowania powierzchni złożonych frezem toroidalnym. Przedmiotem badań była wklęsła oraz wypukła powierzchnia łopatki turbiny ze stopu INCONEL 718. Orientacja osi narzędzia określana jest względem wektora normalnego powierzchni poprzez programowanie kątów wyprzedzenia lub/i pochylenia. Określono wpływ 5-osiowych parametrów orientacji osi narzędzia oraz zmiennego promienia krzywizny na siły skrawania. Słowa kluczowe: symultaniczne 5-osiowe frezowanie, siły skrawania, powierzchnie złożone EFFECT OF TOROIDAL CUTTER AXIS ORIENTATION ON THE CUTTING FORCES IN THE FIVE-AXIS MACHINING OF SCULPTURED SURFACE TURBINE BLADE OF INCONEL 718Abstract Conducted measurement cutting force components during simultaneous five-axis milling of sculptured surfaces using toroidal cutter. Subject of research was concave and convex surface of the turbine blade of INCONEL 718. The tool axis orientation was determined relative to the surface normal vector by programming lead and / or tilt angle. Based on the obtained the results of research defined the effect of five-axis parameters toroidal cutter orientation and a variable radius of curvature on the cutting forces.

show abstract

“…5. The cutting force coefficients and cutter run-out parameters are derived through machining experiments based on the author's previous works [41]. Table 2 shows the concrete modal parameters, cutting force coefficients and cutter run-out parameters.…”

Section: Example Ii: Experiments Verificationmentioning

confidence: 99%

“…In the experiment, the parameter combinations of spindle speed and axial cutting depth are given as (1,500 rpm, 0.03 m), (1,750 rpm, 0.05 m), (2,000 rpm, 0.01 m), (2,500 Cutter run-out has great effect on the geometric accuracy and cutting forces [41,42]. Consequently, it also has contri-butionsto the vibration of the dynamic machining process.…”

Section: Example Ii: Experiments Verificationmentioning

confidence: 99%

Prediction of stability limit for multi-regenerative chatter in high performance milling

Guo

Sun

Jiang

et al. 2014

Int. J. Dynam. Control

Self Cite

View full text Add to dashboard Cite

Chatter is one of the most important factors that inhibit the improvement of productivity and deteriorate the machined surface quality in milling process. In order to obtain good surface quality, classical machining process usually has to take conservative milling parameters. Based on the authors' previous work, this paper presented a new thirdorder discretization method to compute the stability lobes considering multi-regenerative chatter effect. A mathematical model, which is suitable for the dynamic system with non-uniform pitch cutter or cutter run-out, is first established for multi-regenerative chatter. Then, three examples are performed to test the validity of the proposed method. The first example is for the case that the system takes a non-uniform pitch cutter. In the second example, after the modal parameters, run-out parameters and cutting force parameters are gained from experiments, the stability lobes are predicted using the proposed method and subsequently testified by a series of experiments. The third example is for the case of existing cutter run-out. The final computation and experiment results indicate the effectiveness and validity of the proposed method. It is applicable in high performance machining for achieving a good parameter combination.

show abstract

Numerical simulation and prediction of cutting forces in five-axis milling processes with cutter run-out

Cited by 75 publications

References 29 publications

Fourier Analysis of Milling Force for General Helical Cutters via Spacetime Convolution, Part 1: Model Development

Fourier Analysis of Milling Force for General Helical Cutters via Spacetime Convolution, Part 1: Model Development

Effect of toroidal cutter axis orientation on the cutting forces in the five-axis machining of sculptured surface turbine blade of INCONEL 718

Prediction of stability limit for multi-regenerative chatter in high performance milling

Contact Info

Product

Resources

About