Prediction of cutting forces in helical milling process

Wang, Haiyan; Qin, Xuda; Ren, Chengzu; Wang, Qi

doi:10.1007/s00170-011-3435-y

Cited by 86 publications

(33 citation statements)

References 18 publications

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“…Effect of orbital speed is less significant than the spindle speed or the axial feed. Similar trends of process parameters and thrust force have been reported for titanium alloys elsewhere [13].…”

Section: Effect Of Orbital Speedsupporting

confidence: 85%

“…[Insert Figure 1 here] Recently, high volume of research on helical milling has been published for both experimental study and cutting kinematics [12][13]. Li et al [14] established a three-dimensions (3D) surface topography simulation model base on an improved Z-map model to simulate the surface finish profile generated after a helical milling operation.…”

Section: Introductionmentioning

confidence: 99%

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3D FEM simulation of helical milling hole process for titanium alloy Ti-6Al-4V

Qin

et al. 2015

Int J Adv Manuf Technol

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As an emerging hole-machining methodology, helical milling process has become increasingly popular in aeromaterials manufacturing research, especially in areas of aircraft structural parts, dies, and molds manufacturing. Helical milling process is highly demanding due to its complex tool geometry and the progressive material failure on the workpiece. This paper outlines the development of a 3D finite element model for helical milling hole of titanium alloy Ti-6Al-4V using commercial FE code ABAQUS/Explicit. The proposed model simulates the helical milling hole process by taking into account the damage initiation and evolution in the workpiece material. A contact model at the interface between end-mill bit and workpiece has been established and the process parameters specified. Furthermore, a simulation procedure is proposed to simulate different cutting processes with the same failure parameters. With this finite element model, a series of FEAs for machined titanium alloy have been carried out and results compared with laboratory experimental data. The effects of machining parameters on helical milling have been elucidated and the capability and advantage of FE simulation on helical milling process have been well presented.

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Section: Effect Of Orbital Speedsupporting

confidence: 85%

Section: Introductionmentioning

confidence: 99%

3D FEM simulation of helical milling hole process for titanium alloy Ti-6Al-4V

Qin

et al. 2015

Int J Adv Manuf Technol

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“…R et al [2] presented helical milling is capable of machining H7 quality holes with a surface finish of 0.3 μm Ra in AISI D2 tool steel. Wang et al [3] established an analytical cutting force model of the helical milling which can be utilized to predict the change of cutting force in helical milling process under different cutting conditions. Wangyang Ni [4] studied machining dynamics of orbital drilling and tooling solutions for orbital drilling of aerospace aluminum alloy, titanium alloy, CFRP materials and their compounds, which will help the users to select proper cutting tools and cutting parameters for their specific applications.…”

Section: Introductionmentioning

confidence: 99%

Feasibility Study on the Minimum Quantity Lubrication in High-Speed Helical Milling of Ti-6Al-4V

Qin

Gui

et al. 2012

JAMDSM

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The objective of the present work was to study the effect of the application of minimum quantity lubrication (MQL) in high-speed helical milling of Ti-6Al-4V compared with dry and flood coolant (wet) condition. The single factor experiment to study the relationship between cutting force, hole surface roughness and cutting parameters under various coolant-lubricant conditions were implemented. Tool life under various cooling conditions and fixed moderate cutting parameters have also been studied. Uniform flank wear, micro-chipping, thermal cracking and flaking were the dominant tool failure modes under all coolant-lubricant conditions. It was found that dry condition produced the poorest result in terms of cutting force, tool life and hole surface roughness as general expected. MQL presented comparable performance with flood condition in terms of cutting force and hole surface roughness, and even a better tool life performance than flood condition. This testified the flood condition can be replaced by the MQL condition, thus alleviating pollution and saving cost during helical milling of Ti-6Al-4V process.

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“…In the standard procedure, the cutting force coefficients are identified from average values of the cutting force components measured by a cutting force dynamometer in slot cutting experiments at different feed rates [5,6]. This experimental setup is impractical in modern shop floors due to its high cost and hardware setup complexity.…”

Section: Introductionmentioning

confidence: 99%

Cutting torque and tangential cutting force coefficient identification from spindle motor current

Aggarwal

Nešić

Xirouchakis

2012

Int J Adv Manuf Technol

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This article presents an enhanced methodology for cutting torque prediction from the spindle motor current, readily available in modern machine tool controllers. This methodology includes the development of the spindle power model which takes into account all mechanical and electrical power losses in a spindle motor for high-speed milling. The predicted cutting torque is further used to identify tangential cutting force coefficients in order to predict accurately the cutting forces and chatter-free regions for milling process planning purposes. The developed model is compared with other studies available in the literature, and it demonstrates significant improvements in terms of the completeness and accuracy achieved. The developed model is also validated experimentally, and the obtained results show good compliance between the predicted and the measured cutting torque. The developed enhanced procedure is very appealing for industrial implementation for cutting torque/force monitoring and tangential cutting force coefficient identification.

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Prediction of cutting forces in helical milling process

Cited by 86 publications

References 18 publications

3D FEM simulation of helical milling hole process for titanium alloy Ti-6Al-4V

3D FEM simulation of helical milling hole process for titanium alloy Ti-6Al-4V

Feasibility Study on the Minimum Quantity Lubrication in High-Speed Helical Milling of Ti-6Al-4V

Cutting torque and tangential cutting force coefficient identification from spindle motor current

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