Papers by Keyword: Milling Force

Abstract: Mold steel 3Cr2Mo has been used widely in manufacturing of plastic mold formed parts, owing to fine mechanical properties. However, it is also very difficult to cut mold formed parts of steel 3Cr2Mo due to high hardness. Ordinary NC cutting method of steel 3Cr2Mo is unable to relate to modern mold manufacturing due to bad cutting property, so it is extremely significant for improving cutting property of steel 3Cr2Mo to study the high speed milling technology. On the basis of improving the traditional cutting force formula, the mathematical model of high speed milling force for steel 3Cr2Mo was derived and solved by using the experimental data and constructing matrix equation based on MATLAB software. Comparing with experimental data, the error of mathematical model of high speed milling force could be controlled within 6 percent. Due to high precision the model of high speed milling force can meet practical engineering requirement and has great value in the fields of CAD/CAM/CAE.

Abstract: Machining deformation has always been a bottleneck issue in the manufacturing field of aeronautical monolithic components. On the base of finite element method, the effect of the process steps and tool paths on the workpiece stiffness and the redistribution of residual stress in the machining process of aeronautical frame monolithic component was investigated under the given fixturing scheme. Thus, the prediction of the workpiece deformation can be carried out in reason. The proposed simulation approach to deformation analysis can be used to observe the true characteristic of milling forces and machining deformations. Therefore, the proposed method can supply the theoretical basis for the determination of the optimal process parameters.

Abstract: To represent the relation between force and cutting parameters in milling T10 hardened steel, single factor milling experiments with different cutting parameters were done. The experimental result showed that there exited maximum inflection point in force curve under different speeds, and the relation between force and cutting parameters could not be represented with an uniform mathmatical equation. Respective prediction modal of milling force in low speed and high speed were set up using least-square method, which was significant at level of α=0.0005, and its result of R- test was higher than 0.98. This study indicates that the applicable prediction modals in milling T10 steel with low and high speed are different, predict modals being set up can be used to estimate milling force.

Abstract: A numerical model for prediction of cutting force components in peripheral milling process, including the cutting process damping, is proposed. The cutting process damping creates two components (thrust and tangential) of a dynamic cutting force. The total force model is obtained through numerical integration of the local forces. The effects of tool parameters (diameter, helix angle, number of teeth) on process damping and cutting force distributions are discussed. It is shown that the average value of the process damping and the amplitude of the cutting force increase with increasing the tool diameter. On the other hand, when the tool helix angle increases the process damping increases and the cutting force decreases. The number of tool teeth’s has not an influence on the variation of the damping process and cutting force but an influence on the number of cycles of the periodic cutting process.

Abstract: With FEM software of AdvantEdge, a model was created to analyze cutting force and thermal in the high-speed milling process, this model included a complete milling process of cutter radius. Combined with experiments validation, in high-speed milling, the normal force is greater than the tangential force and result in greater residual stress of that direction, which indicates that mechanical force play an essential part on the formation of residual stress. When the speed is over certain scope, the cutting force decreases, but the cutting temperature has been rising. In Roughing, by limiting the range of high-speed the residual tensile stress impact can be reduced. While in finishing, as the feed rate reducing the residual tensile stress will decrease greatly, improving the surface quality of thin-walled parts.

Abstract: The stability of cutting system is an important research in high-speed machining area. It is widely used in engineering practice. First, this paper studies the milling forces and their change law when milling aluminum alloy through orthogonal experiment. And it solves the milling coefficients. Second, it modal parameters of milling system such as natural frequency, modal mass and equivalent stiffness by hammer experiment. On this basis, it draws the stability lobe about the spindle speed and radial depth of cut and verifies the accuracy of the stability lobe.

Abstract: To resolve the problem of the parts deformation because of the milling force, a finite element model (FEM) of end milling process simulation in milling force field was established. On the base of FEM, we simulate the high-speed end milling type structure of aluminum alloy 7075 parts. We successfully predict the end milling force, obtain the effect between the upper and lower material to the milling force, and Mises stress and the tool length beyond the part.The simulation results show that the lower material can increase the milling force to upper, and upper material can decrease milling force to lower layer.The drilling tool length beyond the part is about 0.5 mm .

Abstract: Under dry cutting conditions, multi-factor orthogonal experiment test method is adopted to carry out experiment of milling gray cast iron HT200 using PCBN indexable face milling tool. Milling force empirical formula model is established by means of least-square method and regression analysis. Significance test of regression equation and regression coefficient prove that the reliability of the established model is high. Test results show among three milling forces, the biggest one is tangential force Fz, the smallest one is radial force Fy, whereas value of axial force Fx is between Fz and Fy. Through analyzing experiment results, relationship of milling parameters influence on milling force is summarized. Recommendation of milling parameter value range is put forward.template explains and demonstrates how to prepare your camera-ready paper for Trans Tech Publications. The best is to read these instructions and follow the outline of this text.

Abstract: Because of its low stiffness and intensity structural features, thin-walled parts affected by milling force, easily produce deformation and vibration among processing. In this paper, by optimizing milling parameters, it can be realized to control the size of the dynamic milling force and the milling state. Then it reaches the purpose to decrease workpiece deformation, and makes processing conditions maintain a stable. It not only reduces deformation caused by the vibration, but also makes thin-walled parts errors meet the tolerance requirements.

Abstract: The Composites are difficult machining materials which widely used in aerospace industry due to their excellent mechanical properties. Tool wear and delamination are considered the major concern in manufacture the parts and assembly. The orthogonal experiment method was used to investigate the milling force of carbon fibred composite with diamond mill tool. The experiments were carried out under air cooling cutting conditions. The experimental results indicated that the feed rate was the most significant fact which affect the average peak value of the milling force. the average milling force decreased with the cutting speed increased and increased with the feed rate and width of cut increased.