The effect of the cutting edge helix angle of the cutter on the cutting force components and vibration acceleration amplitude

Burek, Jan; Żyłka, Łukasz; Płodzień, Marcin; Sułkowicz, Paweł; Buk, Jarosław

doi:10.17814/mechanik.2017.11.155

Cited by 7 publications

(3 citation statements)

References 3 publications

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“…15 It is observed in Hosokawa et al 16 that the tangential and normal force components of milling process decrease significantly with the increase of helix angle. Other experimental investigations 17,18 observed that the decrease of tangential and normal force components with the increase of helix angle is accompanied by increase of the axial force component. Worthy to note are the seemingly contradicting analytical and experimental results in Ozturk et al 4 which indicate that tangential, normal, and axial force coefficients are simultaneously increased with increase of helix angle.…”

Section: Introductionmentioning

confidence: 83%

Geometric definition, rapid prototyping, and cutting force analysis of cylindrical milling tools with arbitrary helix angle variations

Ozoegwu

Eberhard

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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In this work, a method is developed for geometric definition and analysis of cylindrical milling tools having various free-form variations of helix angle. The method is based on replicating a position vector on each cutting edge to generate a point set for the whole tool envelope using piece-wise rotation and magnification matrices which are varied according to mathematical laws describing the intended variable shape of the tool. The computed point sets are applied in additive manufacturing of samples of such tools having non-conventional shape features by transforming the point sets to stereolithography formats that are sliced to guide the 3D-printing processes. This manufacturing route that simplifies the realization of arbitrary helix profiles on milling tools is a major contribution of this work since such tools are gaining popularity for their passive damping of vibrations and reduction of cutting forces but are notoriously difficult to manufacture, limiting their exploitation. Analyses are shown about the effects of the considered variable profiles on milling cutting force. These suggest that cutting forces can be greatly suppressed by the proposed free-form helix angle variations. For example, relative to a conventional fixed helix tool of same mean helix angle, the innovative tools recorded 40.33%–84.42% and 60.53%–67.81% force reductions at axial depths of cut of 1 and 5 mm. This demonstrates that innovative variable tool profiles which can be realized through the simplified rapid prototyping technique are promising for advanced sustainable manufacturing of parts with preferred surface conditions.

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Section: Introductionmentioning

confidence: 83%

Geometric definition, rapid prototyping, and cutting force analysis of cylindrical milling tools with arbitrary helix angle variations

Ozoegwu

Eberhard

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…Large helix angles of the cutting edge, appropriate tool-mounting systems are required to provide sufficient clamping force to prevent the tool from slipping out due to the high axial component of the cutting force. It should be also remembered not to exceed the permissible axial force in the spindle of the machine tool [7]. Rake angles come in two assortments, positive and negative.…”

Section: Introductionmentioning

confidence: 99%

Designing a special cutting tool for high performance machining of CuZn40Pb2 brass alloy

Çiçek¹

2021

J Adv Manuf Eng

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In order to be competitive in manufacturing industries, it is essential to create high performance machining processes in manufacturing plant. One of the effective ways to improve the performance of machining processes is cutting tools. Although there are various standard cutting tools, it is also possible to design a special tool to have high performance cutting by eliminating the number of steps. This study focuses on designing a new cutting tools to have high performance machining process of one of the commonly known brass alloys, CuZN40Pb2 in mass production. In this study, two teeth form brazed carbide boring tools with different geometries in terms of radial rake angle and cutting-edge radius have been utilized in order to evaluate the machining performance during boring operation of CuZn40Pb2. Edge radius of brazed carbide cutting tools varied to enhance performance of cutting tool and resulting cutting forces and surface quality of machined parts are examined carefully. It illustrated that this designed tool provides high performance cutting by controlling some design parameters including edge radius and rake angle.

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“…In addition, the tangential forces acts on the rake face of the milling cutter in the direction of the cutting velocity and accounts for a significant amount of the total forces generated during the milling operation. The tangential forces decreases with the selection of a cutter with large positive axial rake decreases and vice versa [Yang et al, 2011;Rychokov and Yanyushkin, 2016;Burek et al, 2017]. However, the magnitude of the cutting force components depends on the cutting edge geometry and engagement conditions.…”

Section: Introductionmentioning

confidence: 99%

Modelling and Optimization of the Cutting Forces During Ti6al4v Milling Process Using the Response Surface Methodology and Dynamometer

Daniyan¹,

Tlhabadira²,

Phokobye³

et al. 2019

MM SJ

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The measurement of cutting forces using highly sensitive piezoelectric force sensors is significant in the optimization of the machining process. In this study, the modelling and optimization of the cutting forces during the milling process of Ti6Al4V was carried out using the Response Surface Methodology (RSM) and the dynamometer. The ranges of the process parameters are: cutting speed (250-280 mm/min), feed per tooth (0.06-0.24 mm) and axial depth of cut (0.30-3.0 mm) are varied over four levels while cutting force serves as the response of the designed experiment. The physical experiments were carried out using a DMU80monoBLOCK Deckel Maho 5-axis CNC milling. Three sets of 2-flute, 10 mm corner radius mills was used for the machining operation. A solid rectangular work piece of Ti6Al4V was screwed to the stationary dynamometer (KISTLER 9257A 8-Channel Summation of Type 5001A Multichannel Amplifier) mounted directly to the machine table. Milling operations were performed using different cutting parameters of cutting speed, feed per tooth and depth of cut and data were collected through Data Acquisition (DAQ) connected to the computer. The numerical experiment produced a mathematical model for predicting the values of the cutting forces as a function of the independent process parameters while the physical experiment revealed that the piezoelectric sensor is highly sensitive to variations in the values of the cutting force.

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The effect of the cutting edge helix angle of the cutter on the cutting force components and vibration acceleration amplitude

Cited by 7 publications

References 3 publications

Geometric definition, rapid prototyping, and cutting force analysis of cylindrical milling tools with arbitrary helix angle variations

Geometric definition, rapid prototyping, and cutting force analysis of cylindrical milling tools with arbitrary helix angle variations

Designing a special cutting tool for high performance machining of CuZn40Pb2 brass alloy

Modelling and Optimization of the Cutting Forces During Ti6al4v Milling Process Using the Response Surface Methodology and Dynamometer

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