Mechanistic modeling of cutting forces in milling process by end milling with cutting edges with adjustment angle of 45 degree

Document Type : Research Article

Authors

1 MSc. Student, Department of Mechanical Engineering, Khomeinishahr Branch, Islamic Azad University, Khomeinishahr/Isfahan, Iran

2 Department of Mechanical Engineering, Khomeinishahr Branch, Islamic Azad University, Khomeinishahr/Isfahan, Iran

Abstract

Determination of machining forces in order to calculate the required power and torque for cutting and select the right tools, equipment, and cutting parameters (feed rate, cutting depth, cutting speed) for machining the desired geometry and material prior to the process is significant. The analysis of machining forces is necessary to determine the forces to reduce the cost of performing multiple empirical experiments. In this study, the components of, , and  milling forces with two cutting edges with main adjustment angle were predicted by the mechanistic modeling method by calculating cutting and edge force coefficients. Also, for the first time, the cutting section of the workpiece was designed in order to eliminate the calculating error of the round corner of inserts.To avoid the interaction of the parameters, simultaneous change of cutting speed with feed rate was avoided and 8 experiments with different feed rates but with the same cutting speed were performed. A comparison of the modeled forces curve with the results obtained from the dynamometer shows acceptable agreement.As the feed rate increases, the difference between the predictive and experimental force decreases relative to the increase of force.
 

Keywords

Main Subjects

References

[1] M. Aydın, U. Köklü, Analysis of flat-end milling forces considering chip formation process in high-speed cutting of Ti6Al4V titanium alloy, Simulation Modelling Practice and Theory, 100 (2020) 102039.
[2] L. Zhou, B. Deng, F. Peng, M. Yang, R. Yan, Semi-analytic modelling of cutting forces in micro ball-end milling of NAK80 steel with wear-varying cutting edge and associated nonlinear process characteristics, International Journal of Mechanical Sciences, 169 (2020) 105343.
[3] S. Wojciechowski, M. Matuszak, B. Powałka, M. Madajewski, R.W. Maruda, G.M. Królczyk, Prediction of cutting forces during micro end milling considering chip thickness accumulation, International Journal of Machine Tools and Manufacture, 147 (2019) 103466.
[4] F. Koenigsberger, A.J.P. Sabberwal, An investigation into the cutting force pulsations during milling operations, International Journal of Machine Tool Design and Research, 1(1) (1961) 15-33.
[5] S. Jayaram, S.G. Kapoor, R.E. DeVor, Estimation of the specific cutting pressures for mechanistic cutting force models, International Journal of Machine Tools and Manufacture, 41(2) (2001) 265-281.
[6] E. Budak, Y. Altintas, E.J.A. Armarego, Prediction of Milling Force Coefficients From Orthogonal Cutting Data, Manufacturing Science and Engineering, 118(2) (1996) 216-224.
[7] P. Lee, Y. Altintaş, Prediction of ball-end milling forces from orthogonal cutting data, International Journal of Machine Tools and Manufacture, 36(9) (1996) 1059-1072.
[8] G. Yucesan, Y. Altintas, Prediction of ball end milling forces, ASME Journal of Engineering for Industry 118 (1) (1996) 95–103.
[9] T. Bailey, e. al, Generic simulation approach for multi-axis machining, Manufacturing Science and Engineering, 124(3) (2002) 624-642.
[10] S. Engin, Y. Altintas, Mechanics and dynamics of general milling cutters.: Part I: helical end mills, International Journal of Machine Tools and Manufacture, 41(15) (2001) 2195-2212.
[11] S. Engin, Y. Altintas, Mechanics and dynamics of general milling cutters.: Part II: inserted cutters, International Journal of Machine Tools and Manufacture, 41(15) (2001) 2213-2231.
[12] J. Gradišek, M. Kalveram, K. Weinert, Mechanistic identification of specific force coefficients for a general end mill, International Journal of Machine Tools and Manufacture, 44(4) (2004) 401-414.
[13] G. Yucesan, Q. Xie, A.E. Bayoumi, Determination of process parameters through a mechanistic force model of milling operations, International Journal of Machine Tools and Manufacture, 33(4) (1993) 627-641.
[14] I.G. Euan, E. Ozturk, N.D. Sims, Modeling Static and Dynamic Cutting Forces and Vibrations for Inserted Ceramic Milling Tools, Procedia CIRP, 8 (2013) 564-569.
[15] S. Campocasso, J.P. Costes, G. Fromentin, S. Bissey-Breton, G. Poulachon, A generalised geometrical model of turning operations for cutting force modelling using edge discretisation, Applied Mathematical Modelling, 39(21) (2015) 6612-6630.
[16] R. Kountanya, C. Guo, D. Viens, Time-averaged and Instantaneous Mechanistic Models using Artificial Force Synthesis in Helical End Milling, Procedia Manufacturing, 10 (2017) 737-749.
Amirkabir Journal of Mechanical Engineering
Volume 53, Issue 4 (Special Issue)
July 2021
Pages 2703-2718

Files

Share

How to cite

Statistics