Thermomechanical modelling of oblique cutting and experimental validation

Moufki, Abdelhadi; Devillez, Arnaud; Dudzinski, D.; Molinari, A.

doi:10.1016/j.ijmachtools.2004.01.018

Cited by 126 publications

(96 citation statements)

References 38 publications

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“…This model uses the shear band model developed for high speed machining by Molinari et al [13] and Dudzinski et al [14] and the analytical modelling of the 3D oblique cutting configuration developed by Moufki et al [15]. And now Zeroudi et al [16] have integered in model the use of CAM tool paths and Zeroudi and Fontaine [17] have also predicted the produced form and roughness.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigations from conventional to high speed milling on a 304-L stainless steel

Maurel-Pantel

Fontaine

Guerbet

et al. 2013

Int J Adv Manuf Technol

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Last years analytical or finite element models of milling become more efficient and focus on more physical aspects, nevertheless the milling process is still experimentally unknown on a wide range of use. This paper propose to analyse with accuracy milling operations by investigating the cutting forces values, shape of cutting forces curves obtained for different cutting speeds, and related phenomena as tool wear or tool run-out. These detailed experimental data in milling constitute a suitable experimental basis available to develop predictive machining modelling. All the tests have been conducted on the 304L stainless steel in many cutting configurations and for different tool geometries. The machinability of the 304L stainless steel with different tools geometries and configurations in shoulder milling is defined by three working zones: a conventional zone permitting stable cutting (low cutting speed; under 200-250 m.min -1 ), a dead zone (unfavourable for cutting forces level and cutting stability; between 250 and 450 m.min -1 ), and a high speed machining zone (high cutting speed; up to 450-500 m.min -1 ). All the used criteria (cutting forces, chips, wear) confirm the existence of these different zones and a correlation is proposed with cutting perturbations as run-out, cutting instability, ploughing and abrasive wear.

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Section: Introductionmentioning

confidence: 99%

Experimental investigations from conventional to high speed milling on a 304-L stainless steel

Maurel-Pantel

Fontaine

Guerbet

et al. 2013

Int J Adv Manuf Technol

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“…While Ozturk and Tunc presented the detailed analysis of lead and tilt angle's effects on cutting forces, torque, form errors and stability [16]. Also researches that dealt with the effects of tool-surface inclination on ball end mill cutting forces were conducted by using thermomechanical modeling of oblique cutting [17,18]. Based on this model, Fontaine et al launched several experiments with straight tool paths and various tool-surface inclinations on a 3-axis machine.…”

Section: Advances In Mechanical Engineeringmentioning

confidence: 99%

Prediction and Experimental Validation of Cutting Force for Bull-Nose End Mills with Lead Angle

Gao

Luo

et al. 2014

Advances in Mechanical Engineering

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This study focuses on cutting force predictions with the tool-workpiece inclination angle in bull-nose milling based on the semimechanistic force model. By analyzing kinematics and mechanics of the bull-nose end mills during cutting, force expressions including lead angle are stated and the model is exerted on each discrete element as oblique cutting with coordinate transformation and numerical integration to obtain the dynamic cutting force components. An improved identification method considering speed variations along the tool axis is applied to calibrate coefficients. Coefficients are regarded as the function of each elemental elevation. Then, a geometry-based method to acquire cutter workpiece engagement (CWE) is proposed. Also acquisition of accurate start and exit angles on each slice is deliberated elaborately for cutters with lead or tilt angle in milling processes. Thereby, to verify the validity of the force prediction model and start-exit angle acquisition method, experiments with variable lead angles are conducted under different axial immersions. The results reveal that the presented model and approaches can predict cutting forces with high accuracy. Finally, the cutting force components under different cutter postures and conditions are analyzed to provide instructions for parameter selections.

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“…Recent publications still concern the analytical approaches and give more accurate results on cutting forces [43,44,45] in different kind of cutting conditions [46]. Some of them focuse on specific aspects such as the white layer apparition [47] or the burr formation [48].…”

Section: Overviews Of the Current Approachesmentioning

confidence: 99%

“…e trial n+1 (46) we obtain, after some calculations, the following incremental law for F p (see [104,105,106]):…”

Section: Numerical Integration Of the Constitutive Equationsmentioning

confidence: 99%

Contribution of computational mechanics in numerical simulation of machining and blanking: State-of-the-Art

Lorong

Yvonnet

Coffignal

et al. 2006

Arch Computat Methods Eng

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HAL is a multi-disciplinary open access archive for the deposit and dissemination of scientific research documents, whether they are published or not. The documents may come from teaching and research institutions in France or abroad, or from public or private research centers. L'archive ouverte pluridisciplinaire HAL, est destinée au dépôt et à la diffusion de documents scientifiques de niveau recherche, publiés ou non, émanant des établissements d'enseignement et de recherche français ou étrangers, des laboratoires publics ou privés. SummaryBlanking and machining are commonly used in processes to obtain the shape of many mechanical pieces. Although considerable number of experimental results exist, certain essential aspects of cutting are still not well understood. This comes from the complexity of the thermomechanical phenomena induced by the material separation as well as from the complexity of the dynamical behaviour of the whole workpiece/tool/machine system. Numerical simulations make it possible to go further in the comprehension and the prediction of machining and cutting processes. In this work the state-of-the art is analysed and we present the most recent developments in the contribution of computational mechanics to numerical simulation of machining and blanking. This contribution is, on one hand, developed at a very global scale called macroscopic scale. At this scale a representation of the deformations of the piece is necessary, for example when thin walls are present, and when both predictions of the geometrical state of final surface and/or stability of the process are expected. On the other hand, the contribution is also located at a more local scale: the mesoscopic scale. At this scale, the aim is the determination of thermomechanical sollicitations applied to the tool, the simulation of chip formation, or the description of residual states (mechanical, chemical) inside the workpiece after machining.

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Thermomechanical modelling of oblique cutting and experimental validation

Cited by 126 publications

References 38 publications

Experimental investigations from conventional to high speed milling on a 304-L stainless steel

Experimental investigations from conventional to high speed milling on a 304-L stainless steel

Prediction and Experimental Validation of Cutting Force for Bull-Nose End Mills with Lead Angle

Contribution of computational mechanics in numerical simulation of machining and blanking: State-of-the-Art

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