Papers by Keyword: Peripheral Milling

Abstract: Due to the deflection of tool and workpiece induced by cutting force, there is a high complexity associated with the prediction of surface form errors in the peripheral milling process of thin-walled workpieces. And the prediction of surface form errors induced by cutting deflection is the precondition for process optimization and error compensation. This paper proposes a systematic simulation procedure suitable for surface form errors prediction in peripheral milling of low rigid thin-walled workpiece. Some key algorithms with the judgment of contacts between the cutter and the workpiece, the flexible iterative algorithm as well as the tool/workpieces deflection prediction using FE model are developed and presented in detail. Comparisons of the form errors and cutting forces obtained numerically and experimentally confirm the validity of the proposed algorithms and simulation procedure.

Abstract: In this paper, an advanced 3D FE model was established using ABAQUS Explicit to simulate the process of milling aluminum-alloy 7075-T7451. Taking the end edge and the side edge of single flute into consideration, the model simulated the interaction between the spiral flute and wokpiece at full depth of cut. In addition, by defining automatic element deletion criterion and locally refining mesh, this model realized chip separating from workpiece without defining of cutting layer. The simulation results were compared with experimental data to verify the correctness of the simulation model.

Abstract: In high speed machining, temperature distribution in workpiece is the main factor which directly affects the surface integrity and dimensional accuracy of machined workpiece. In this paper, the machined workpiece temperature in high speed peripheral milling is analyzed through using moving heat source method and inverse method. Firstly, the workpiece to be machined is considered as a semi-infinite solid to model the transient surface temperature using arc-shaped moving heat source. Inverse method is then applied for the calculating of heat flux. Peripheral milling experiments of 1045 steel is performed with coated carbide insert The machined surface temperatures were measured during experiments. The measured results were found to be in agreement with the predicted ones by transient models for machined surface temperatures. These results confirm the conclusion that the transient workpiece temperature will decline when the cutting speed increases to a critical value.

Abstract: Analysis of instantaneous uncut chip thickness (IUCT) in peripheral milling of curved surface with variable curvature is nontrivial due to the combined influences of both process geometry and cutter runout. This paper gives a systematic analysis of IUCT including the effects of changing workpiece geometry and the cutter runout in peripheral milling. The prominent feature of this analysis procedure lies in that the novel equation for computing the IUCT is mathematically derived in detail. Numerical simulations are performed to study the effect of workpiece curvature and cutter runout on IUCT. The proposed model is validated by comparing the measured cutting forces with those predicted based on the IUCT which is obtained using the current approach.

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: This paper proposes a new efficient iterative algorithm which named flexible iterative algorithm (FIAL) with a general approach suitable for surface form errors prediction in peripheral milling of thin-walled workpiece. First, a FEA-Based model is presented to analyze the surface dimensional errors in peripheral milling of thin-walled workpieces. Then the FIAL is discussed in detail for the procedure of deformation prediction. From FIAL, an iterative scheme for the calculations of tool/workpiece deflections considering the former convergence cutting position are developed，in the scheme a small variable must be included in the calculation of radial cutting depth which never been considered in the literatures before.The proposed approach is validated and proved to be efficient through comparing the obtained numerical results with the test results.