Predictive modelling of cutting forces in end milling of titanium alloy Ti6Al4V

Chen, Yun; Li, Huaizhong; Wang, Jun

doi:10.1177/0954405416673108

Cited by 15 publications

(13 citation statements)

References 34 publications

(45 reference statements)

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“…And the undeformed chip thickness is calculated with respect to pre-defined tool coordinate system, which is regarded as the transformation form of feed cross-feed normal system by lead and tilt angles. Chen et al 18 presented a model assuming a semi-stationary process for the serrated chip formation. To extend the predictive model to milling, the end mill is discretized into several axial slices, and an equivalent cutting edge is used to include the end cutting edge effect caused by the first axial slice.…”

Section: Introductionmentioning

confidence: 99%

A modeling and prediction method for plunge cutting force considering the small displacement of cutting layer

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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In the process of plunge milling, the main cutting force is along the axial direction, and usually, the machining system has good axial rigidity, so it can withstand large cutting loads. This characteristic makes plunge milling particularly suitable for high-efficiency rough machining and semi-finishing of difficult-to-cut materials. The cutting force in the plunge milling process is usually large, and when the process parameters are not selected properly, the plunge milling is prone to the back-off phenomenon. In view of the characteristics of large cutting force and high cutting temperature in Inconel 718 plunge milling process, considering the small displacement of the actual tool tip caused by cutting force and cutting vibration, this article establishes a plunge milling force model based on the combination of analytical method and three-dimensional finite element method. The micro-displacement caused by vibration is obtained through dynamic modeling and modal test methods. Combined with the macro-displacement of cuter back-off under the action of the cutting force during the single-tooth run-in and run-out process, the modified cutting layer parameters are obtained, and optimized cutting force of plunge milling is obtained.

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Section: Introductionmentioning

confidence: 99%

A modeling and prediction method for plunge cutting force considering the small displacement of cutting layer

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…Therefore, earlier works used numerical methods to study the machining mechanism based on flow stress. 6–8 Metal plastic behaviors have been evaluated by deriving material constitutive models. 9–12 The Johnson-Cook (JC), Zerilli-Armstrong (ZA), Bodner-Partom (BP), and Khan-Huang (KH) models are typical plasticity models that can be used to analyze materials with different properties.…”

Section: Introductionmentioning

confidence: 99%

Simulation of the round insert face milling process of AISI 316LN stainless steel with machining-based plastic behavior modeling

Kim

Kwon³

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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A proper plastic behavioral model is required to simulate metal cutting. Here, we model the plastic behavior of AISI 316LN stainless steel during face milling. We used a numerical approach to derive a plasticity model appropriate for machining; a two-dimensional cutting force prediction and a genetic algorithm were conducted for that. The force prediction was performed considering a geometrical relationship between the work material and cutting tool. We used the Johnson-Cook (JC) constitutive material model, and initial model parameters were obtained via tension testing at low strain rates (0.001–1 s−1). The genetic algorithm optimized the model parameters; the predictive accuracy with respect to cutting force was high in the model with optimized parameters. We used the optimized JC model for finite element analysis and simulated face milling with a round insert. We measured the cutting forces to validate our modeling approach; the simulated and measured principal forces were in good agreement (error rate ≤ 3.9% under all machining conditions). Our model improved the accuracy of plastic behavior prediction by 93.0% versus the original model. The high accuracy was retained even when the machining environment changed.

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“…Researchers have made much effort to understand the IUCT forming mechanism in the micro-milling process. Y Chen et al 24 presented a cutting force model using the mechanical theory regarding one-parameter cutter runout. These studies have made great advances to push forward the micro-machining technologies.…”

Section: Introductionmentioning

confidence: 99%

An accurate instantaneous uncut chip thickness model combining runout effect in micro-milling using cutters with the non-uniform helix and pitch angles

Guo

Jiang

Yang

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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As a key factor, the accuracy of the instantaneous undeformed thickness model determines the force-predicting precision and further affects workpiece machining precision in the micro-milling process. The runout with five parameters affects the machining process more significantly compared with macro-milling. Furthermore, modern industry uses cutters with non-uniform pitch and helix angles more and more common for their excellent properties. In this article, an instantaneous undeformed thickness model is presented regarding cutter runout, variable pitch, and helix angles in the micro-milling process. The cutter edge with the cutter runout effect is modeled. Then, the intersecting ellipse between the plane vertical to the spindle axis and the cutter surface which is a cylinder can be gained. Based on this, the points, which are used to remove the material, on the ellipse as well as cutter edges are calculated. The true trochoid trajectory for each cutting point along the tool path is built. Finally, the instantaneous undeformed thickness values are computed using a numerical algorithm. In addition, this article analyzes runout parameters’ effects on the instantaneous undeformed thickness values. After that, helix and pitch angles’ effects on the instantaneous undeformed thickness are studied. Ultimately, the last section verifies the correctness and validity of the instantaneous undeformed thickness model based on the experiment conducted in the literature.

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Predictive modelling of cutting forces in end milling of titanium alloy Ti6Al4V

Cited by 15 publications

References 34 publications

A modeling and prediction method for plunge cutting force considering the small displacement of cutting layer

A modeling and prediction method for plunge cutting force considering the small displacement of cutting layer

Simulation of the round insert face milling process of AISI 316LN stainless steel with machining-based plastic behavior modeling

An accurate instantaneous uncut chip thickness model combining runout effect in micro-milling using cutters with the non-uniform helix and pitch angles

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