Papers by Keyword: Cutting Force Model

Abstract: Two generalized cutting schemes predetermining the machining error formation mechanism are distinguished: contour machining, when the profile of the machined surface is formed by the corresponding tool path - contour machining; profile machining, when the profile of the machined surface is formed by the corresponding tool profile - shaped tool machining. For the trajectory scheme, the known force relations are generalized to a spatial curvilinear trajectory. Generalized dependencies for the cutting force components of form, slotted, cut-off and groove cutters are derived for the profile scheme. The evaluation of the adequacy of the proposed model for cutting force components is carried out on the basis of a specially conducted experimental research of the profile turning process with direct measurement of forces at different levels of varying technological factors. Thus, the developed dependences of the coordinate components of cutting forces on technological factors (parameters of cutting conditions, strength properties of the processed material, deformation properties of the technological system, etc.) allow using them for the practical application of machining error models in the matrix theory of multitool machining accuracy.

Abstract: The paper presents a mathematical model for calculating cutting forces during the machining of 16MnCr5 steel using the Sandvik CNMG 120408 16P25T tool. The modeling process involved the use of a test rig constructed based on the 16Д25 machine, which enabled the measurement of real values of spindle speed, longitudinal feed, cutting depth, and cutting forces. The results transmitted to a computer through the LTR-EU-8 workstation, equipped with galvanic isolated LTR modules and a synchronization interface. Based on the experimental results, the theoretical model demonstrated a deviation from actual measurements of no more than 4.72%. The study provides evidence that the cutting force calculations commonly presented by leading tool manufacturers are inherently overestimated. he difference in cutting forces can be 9%.

Abstract: Orthogonal-to-oblique transformation model, which is formulated based on the cutting database including shear stress, shear and friction angles, can be used to predict cutting forces in high speed milling process and any other machining process. The involved shear stress, shear and friction angles are traditionally identified from abundant number of turning experiments. For the purpose of saving experimental cost, this paper presents a novel method to identify these parameters directly from flat end milling processes. Identification procedures are established by transforming the cutting forces measured in Cartesian coordinate system into a local system. The advantage lies in that in spite of the cutter geometries and cutting conditions, only a few tests are required to develop the model, which is experimentally validated to be effective for predicting the cutting force in terms of magnitude and shape in other machining cases.

Abstract: A mechanistic model capable of predicting end milling cutting forces in brittle porous media is described. A coefficient which is capable of reproducing the random shape and variation in cutting forces due to porosity is proposed. In addition, a method of experimental determination of cutting force coefficients is outlined. The proposed model is based on the hypothesis that the random shape and variation in cutting forces of brittle porous media coincide with the shape and variation of pore size and distribution in the media. The developed coefficient and model is compared to end milling tests conducted in CB1100, a porous machinable alumina based ceramic manufactured by UMECO. High correlation between predicted and measured cutting forces is shown. Experiments show that the model is capable of accurate prediction of variation in individual cutting tooth force profile shape and overall magnitude over the entire range of machining conditions tested. The benefit of the model lies in its ability to greatly reduce the number of cutting tests required when investigating cutting forces in novel brittle porous materials.

Abstract: Cutting force equation was established for milling with flat end cutter as feeding in straight-line path by means of discretization method. The model of milling force was conducted based on the manufacturing character of cylindrical surface. The milling force is continual change in manufacturing process, it’s not only influenced by milling parameter, but also related with the shape of cam’s contour. Milling force can result in vibration as machining. Milling force prediction is very useful for manufacturing accuracy control.

Abstract: The depth of cut changed periodically along the contour of the cutting surfaces. The diamond tool of sharp point tip was used in diamond cutting microstructured surfaces with Fast Tool Serve (FTS). All reported the cutting force model were not suitable for accurately predicting cutting force. A cutting forces model concerned with edge radius, spring back and dynamic shear angle was proposed for diamond cutting microstructured surfaces. The model was verified with a series of experimental results. The results showed that the proposed model was able to exactly predict the cutting force.

Abstract: Elliptical vibration cutting (EVC) is one of the main methods to use diamond tool machining of hard to cutmaterial. Accurate prediction of cutting force in elliptical vibration cutting process is not only an important basis to properly choose of cutting parameters and optimal tool geometry parameters, but also a key factor to improve the processing property of cutting. A method to build cutting force theory model in EVC is presented in this paper. Eigen decomposition of the elliptic motion locus first ,then getting the piecewise function of the cutting force model. Based on simulation analysis of the cutting force model, this paper predict the rules that vibration amplitude and angle of tool geometry affect on cutting force, which provide theory basis for choose cutting parameters and cutting tool parameter in EVC.

Abstract: This paper aims at studying a method to identify the cutter runout parameters for end milling. An analytical cutting force model for end milling is proposed to predict cutting force. The cutting force is separated into a nominal component independent of the cutter runout and a perturbation component induced by the cutter runout. Using the cutting force acting on the and directions to calculate the difference between the cutting radius of the adjacent tooth. Then runout parameters are obtained after a series of data processing. The simulation and the experimented results are made to validate the presented methods.

Abstract: This paper makes the emulate experimental research of cutting force in high-speed dry gear milling by flying cutter with finite element analysis method by using the established cutting force model yet, makes the comparative analysis for the result of simulation experiment and theoretical calculation, verifies the correctness of cutting force model and calculation method, makes the comparative analysis for the influencing relations and changing laws of cutting force and cutting parameters and so many factors, and reveals the cutting mechanism of high-speed dry gear milling by flying cutter initially. By the research of this paper, it provides basic theory for subsequent cutting machine technology of high-speed dry gear hobbing, and establishes the theoretical basis for the spread and exploitation of this technology.

Abstract: Milling force is an important parameter during machining, which is directly related to the tool deformation, the tool life, the quality of the part surface, cutting heat, etc. In actual production, the cutting force on inside corner is more complex than the linear. For lack of the accurate cutting force information, there is liable to cause over-cut and owes-cut, rough surface, cutter breaking phenomenon. According to the structural characteristics of the corner, the cutting force model is established, which cutting force is further subdivided and the overall prediction accuracy is improved. Effects of different helix angle and forward amount each gear on cutting force. A good agreement is shown between the model simulation and the results of the experimental ones. The research provides a theoretical basis of predicting the cutting force on inside corner, and it is also helpful for further and practice.