Prediction of Milling Force Based on Numerical Simulation of Oblique Cutting

Wang, B. S.; Zuo, Jianyong; Wang, M. L.; Hou, Junming

doi:10.1080/10426914.2011.654150

Cited by 16 publications

(8 citation statements)

References 15 publications

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“…Figure 6 displays the variation of interface pressure, interface temperature, resultant cutting force, and wear rate obtained with a variation in the depth of cut. An increase in interface temperature, interface pressure, and resultant cutting force is observed, and simultaneously a reduction in the wear rate is obtained with an increase in the depth of cut values [39][40][41][42].…”

Section: Resultsmentioning

confidence: 93%

Numerical Modelling, Simulation, and Analysis of the End-Milling Process Using DEFORM-3D with Experimental Validation

Senthilkumar

Hariharan

Tamizharasan

et al. 2022

Advances in Materials Science and Engineering

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In this present work, finite element analysis (FEA)-based simulation of end-milling of AISI1045 steel using tungsten carbide tool was performed using DEFORM-3D simulation software. Usui tool wear model, Johnson-cook material model and adaptive remeshing are considered during machining simulation. The impact of machining variables rate of feed, tool speed, and depth of cut was investigated, and the best integration of variables was distinguished for lower cutting temperature, principal stress, cutting forces, effective stresses, tool wear, and effective strain. The obtained results were correlated using experimentation in a vertical machining center attached with a Kistler tool dynamometer with data acquisition setup for capturing the cutting forces, and an infrared (IR) thermometer was used to measure the cutting temperature, and a comparison was done. Results showed a good correlation. There is a relationship between experimental and numerical results, and simulation findings can be utilised for interpreting the influence of machining parameters.

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Section: Resultsmentioning

confidence: 93%

Numerical Modelling, Simulation, and Analysis of the End-Milling Process Using DEFORM-3D with Experimental Validation

Senthilkumar

Hariharan

Tamizharasan

et al. 2022

Advances in Materials Science and Engineering

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“…Their simulation demonstrates that more convincing results are obtained using the parabolic than the triangular heat-flux distribution. Wang et al [11] developed a finite element model to simulate the cutting process and reflects the effects of high temperature, large strain, and strain rate to the workpiece material. They deduced the relationship between cutting force coefficients and chip thickness.…”

Section: Introductionmentioning

confidence: 99%

Investigating Tool Wear, Chip Behaviour and Spring Back Action Using FEM

2022

MSA Engineering Journal

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The tool wear found in machining processes represents main obstacle for machinability due to its detrimental effects on surface roughness, material removal rate and machining economy. A nonlinear thermomechanical finite element model was developed to simulate the tool chip interaction. This model predicts not only the chip morphology and chip flow direction, cutting forces values, stress distribution, but also can use to predict tool wear. Furthermore, the effect of elastic deformation (spring back) and the thermal effect have been considered in the model. Cutting force was predicted and compared with the conducted experimental work. Dry turning operation was carried out on low carbon steel using carbide tool. The tool/workpiece interface stress on flank face was calculated and compared with the FEM. Predicted results show good correlation with the FEM. FE model was verified experimentally by measuring the cutting force. The friction on the flank face and spring back concentrates the stress on the flank face.

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“…The FE based simulation effectively saves the physical resources and time required for experimentation, thus reduces the overall machining cost. However, commercial FE software is too expensive and demand exclusive expertise in the subject domain to successfully simulate any machining process, which may not be viable for small and medium scale industries [11]. Also, the simulation accuracy depends on material constitutive models, bond-sliding models, and friction models used to express the toolwork engagement.…”

Section: Introductionmentioning

confidence: 99%

“…However, one needs to ensure accuracy by considering the deviation between simulation results and experimental data. Since FE simulations are based on some basic assumptions, like perfectly rigid tool body, sharp cutting edge, isotropic work material and viscoplastic etc., that limits the accuracy of results [11,12]. The analytical studies rely mostly on mechanistic force model (semi-analytical method) considering cutting coefficients or on complex cutting mechanics at cutting zone (purely analytical method) considering the thermo-mechanical properties and applied cutting parameters as depicted in Fig.…”

Section: Introductionmentioning

confidence: 99%

A mechanistic approach to predict cutting forces based on cutting force coefficients in slot milling Al-7075

Mali¹,

Chinchanikar²,

Gupta

2022

Preprint

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The force in metal cutting is a crucial factor that determines surface quality, tool wear, and cutting stability. It has a significant role in defining the power requirement, machine and cutting tool specifications which govern the overall machining time and cost. In this study, a force prediction approach is presented using cutting force coefficients evaluated in slot milling Al-7075 based on Taguchi's design of experiments. The adopted mechanistic approach is the inverse way to evaluate milling forces by solving the analytical models using known (measured) cutting force data. A total of 27 slot milling experiments are performed by varying the speed, feed and cutting depth to get the main effect plots considering mean values of feed and cutting forces. These plots show a strong linear correlation between feed per tooth and milling forces. Accordingly, the linear force components (Fic and Fie) and corresponding cutting force coefficients (Kic, and Kie,) are evaluated considering analogy with an equation of line. The shearing action in metal cutting is represented by shear force coefficients and plowing, friction, and rubbing action is reflected with friction/edge force coefficients. Subsequently, the forces in milling are estimated based on these force coefficients for predefined input parameters. The force coefficients and corresponding forces are also evaluated using classical mechanistic approach and results are compared. The accuracy of presented approach is verified through confirmation tests showing approximately 5 % average error compared to experimentally measured forces.

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Prediction of Milling Force Based on Numerical Simulation of Oblique Cutting

Cited by 16 publications

References 15 publications

Numerical Modelling, Simulation, and Analysis of the End-Milling Process Using DEFORM-3D with Experimental Validation

Numerical Modelling, Simulation, and Analysis of the End-Milling Process Using DEFORM-3D with Experimental Validation

Investigating Tool Wear, Chip Behaviour and Spring Back Action Using FEM

A mechanistic approach to predict cutting forces based on cutting force coefficients in slot milling Al-7075

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