Cutting Force Modeling and Prediction in End Milling Including Flank Wear

Abstract:

A mechanistic approach for the prediction of end milling including tool wear is proposed in this paper. The additional cutting force caused by increase of flank wear is considered. Total cutting force is regarded as the summation of the rake-face force and flank-face force. Cutting force coefficients are identified by the cutting tests of various cutting parameters combination on 300M steel. Then the cutting force coefficients models are established based on the cutting parameters. The prediction of cutting force obtained by numerical method is validated by the cutting experiments.

• Periodical: Advanced Materials Research (Volumes 690-693)
• Pages: 2427-2436
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.690-693.2427
• Online since: May 2013
• Authors: Jie Wen, Fang Yu Peng, Sen Lin, Rong Yan, Yi Zhi Liu
• Keywords: Cutting Force Modeling, End Milling, Flank Wear, Force Coefficients Calibration

References

[1] Quanren Zeng, Geng Liu, Lan Liu. Quantitative description model of surface integrity for machined parts [J]. China Mechanical Engeering. 21(2010) 2995-3008. In Chinese.

[2] Cai Xu, Xianli Liu. Research progress of machined surface integrity for high stess steel cutting process [J].Journal of Harbin University of Science and Technology. 16(2011) 5-10. In Chinese.

[3] Baoguo Zhang, Zhitong Chen, Yaoxi Xiong. Experimental research on tool wear in milling 300M with coated tool [J]. Aviation Precition Manufacturing Technology, 44(2008) 41-44. In Chinese.

[4] Xue Yan, Hua Tao,Xiaobing Gao. Study on modeling of cutting force for 300M ultra-high-strengh steel in high-speed milling process [J]. Journal of Mechanic Strength. (30)2008 860-863. In Chinese.

[5] Altintas Y. Manufacturing Automation [M]. London：Cambridge University Press, 2000.

[6] M.Y. Yang, H.D. Park. The prediction of cutting forces in ball-end milling [J]. International Journal of Machine Tools & Manufacture. 31(1991) 45-54.

DOI: 10.1016/0890-6955(91)90050-d

[7] Binglin Li, Yujin Hu, Xuelin Wang. Cutting force prediction based on oblique cutting theory end milling [J]. China Mechanical Engeering. 22(2011) 2283-2288. In Chinese.

[8] Lee P, Altintas Y. Prediction of ball end milling forces from orthogonal cutting data [J]. International Journal of Machine Tools & Manufacture. 36(1996) 1059-1072.

DOI: 10.1016/0890-6955(95)00081-x

[9] Larue A, Anselmetti B. Deviation of a machined surface in flank milling, International Journal of Machine Tools and Manufacture. 43(2003) 129-138.

DOI: 10.1016/s0890-6955(02)00189-x

[10] Jian-Wei Dang，Wei-Hong Zhang. Cutting force modeling for flat end milling including bottom edge cutting effect [J]. International Journal of Machine Tools & Manufacture. 50(2010) 986-997.

DOI: 10.1016/j.ijmachtools.2010.07.004

[11] Lamikiz A, de Lacalle LNL, Sanchez JA, Salgado MA. Cutting force estimation in sculptured surface milling [J]. International Journal of Machine Tools & Manufacture, 44(2004) 1511-1526.

DOI: 10.1016/j.ijmachtools.2004.05.004

[12] Qingyuan Cao, Deyi Xue, Jun Zhao, Yueen Li. A cutting force model considering influence of radius of curvature for sculptured surface machining [J]. International Journal of Advanced Manufacturing Technology, 54(2011) 821-835.

DOI: 10.1007/s00170-010-2980-0

[13] Wan M，Zhang W H，Qin G H. Efficient calibration of instantaneous cutting force coefficients and runout parameters for general end mills [J]. International Journal of Machine Tools & Manufacture. 47(2007) 1767-1776.

DOI: 10.1016/j.ijmachtools.2006.06.012

[14] Teitenberg T M, A E Bayoumi, G Yuscesan. Tool wear modeling through an analytic mechanistic model of milling processes [J]. Wear. 154(1992) 287-304.

DOI: 10.1016/0043-1648(92)90160-a

[15] Xiwen Li, Runsheng Du, Shuzi Yang. Tool wear modeling of milling cutter baesd on flank wear area [J]. Journal of Huazhong University of Science and Technology. 29(2001) 53-56. In Chinese

[16] M. Ben Said, K. Sai. An investigation of cutting forces in machining with worn ball-end mill[J]. Journal of Materials Processing Technology. 209(2009) 3108-3127.

DOI: 10.1016/j.jmatprotec.2008.07.028