Journal articles: 'Cutting force. eng'

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López de Lacalle, Luis Norberto, Gorka Urbicain Pelayo, Asier Fernández-Valdivielso, Alvaro Alvarez, and Haizea González. "Wear-dependent specific coefficients in a mechanistic model for turning of nickel-based superalloy with ceramic tools." Open Engineering 7, no. 1 (2017): 175–84. http://dx.doi.org/10.1515/eng-2017-0024.

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AbstractDifficult to cut materials such as nickel and titanium alloys are used in the aeronautical industry, the former alloys due to its heat-resistant behavior and the latter for the low weight - high strength ratio. Ceramic tools made out alumina with reinforce SiC whiskers are a choice in turning for roughing and semifinishing workpiece stages. Wear rate is high in the machining of these alloys, and consequently cutting forces tends to increase along one operation.This paper establishes the cutting force relation between work-piece and tool in the turning of such difficult-to-cut alloys by means of a mechanistic cutting force model that considers the tool wear effect. The cutting force model demonstrates the force sensitivity to the cutting engagement parameters (ap, f) when using ceramic inserts and wear is considered.Wear is introduced through a cutting time factor, being useful in real conditions taking into account that wear quickly appears in alloys machining. A good accuracy in the cutting force model coefficients is the key issue for an accurate prediction of turning forces, which could be used as criteria for tool replacement or as input for chatter or other models.

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Yangui, Hedi, Bacem Zghal, Amir Kessentini, et al. "Influence of Cutting and Geometrical Parameters on the Cutting Force in Milling." Engineering 02, no. 10 (2010): 751–61. http://dx.doi.org/10.4236/eng.2010.210097.

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FOSTER, A. D., J. LIN, D. C. J. FARRUGIA, and T. A. DEAN. "A STRESS STATE DEPENDENT DAMAGE MODEL FOR THE HIGH TEMPERATURE FAILURE OF FREE-CUTTING STEELS." Journal of Multiscale Modelling 01, no. 03n04 (2009): 369–87. http://dx.doi.org/10.1142/s1756973709000189.

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Free-Cutting Steels (FCS), also referred to as Free Machining Steels, are characterised by their excellent chip formation and low cutting force during machining. However, the microstructure features which provide the advantageous machining properties have been linked to poor formability during secondary processing such as those occurring during hot rolling of bar products (Y. Liu et al., On micro-damage in hot metal working Part 1: Experimental investigation, Eng. Trans.54 (2006) 271–287). In this paper physically-based modelling equations are formulated from microstructure and flow stress observations, specifically for the high temperature deformation of FCS. The isotropic, viscoplastic-damage and stress state dependent material model is determined for a typical low-carbon FCS. The model is integrated with the commercial FE code ABAQUS Explicit through user routine VUMAT. Results are validated with the recently introduced conical splay test.

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Buckner, G. D. "Erratum: “Intelligent Sliding Mode Control of Cutting Force During Single-Point Turning Operations” [ASME J. Manuf. Sci. Eng., 123, No. 2, pp. 206–213]." Journal of Manufacturing Science and Engineering 125, no. 1 (2003): 179. http://dx.doi.org/10.1115/1.1537742.

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Matsumura, Takashi, Motohiro Shimada, Kazunari Teramoto, and Eiji Usui. "Predictive Cutting Force Model and Cutting Force Chart for Milling with Cutter Axis Inclination." International Journal of Automation Technology 7, no. 1 (2013): 30–38. http://dx.doi.org/10.20965/ijat.2013.p0030.

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A force model for milling with cutter axis inclination is presented. The model predicts the cutting force and chip flow direction. Three-dimensional chip flow is interpreted as a piling up of the orthogonal cuttings in the planes containing the cutting velocities and the chip flow velocities in the inclined coordinate system with a ball end mill. The chip flow direction is determined to minimize the cutting energy consumed into the shear energy on the shear plane and the friction energy on the rake face. Then, the cutting force is predicted in the chip flow determined model. The presented cutting model is verified by comparing the predicted cutting forces to the measured forces in the actual cutting tests. As an advantage of the presented force model, the change in the chip flow direction during one rotation of the cutter is also predicted in the simulation for the cutter axis inclination and the cutting parameters. In the simulation, the effect of cutter axis inclination on the cutting process is discussed in terms of the tool wear and surface finish. The cutting force charts, in which the maximum values of the positive and the negative cutting forces are simulated for the inclination angles, are presented to review the cutter axis inclination. The applicable cutter axis inclination can be determined by taking into account the thresholds of the cutting force components.

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Wu, Wei Guo, Gui Cheng Wang, and Chun Gen Shen. "Analysis of Cutting Forces in Helical Ball-End Milling Based on Coordinate Conversion." Advanced Materials Research 139-141 (October 2010): 917–20. http://dx.doi.org/10.4028/www.scientific.net/amr.139-141.917.

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In this work, the prediction and analysis of cutting forces in helical ball-end milling operations is presented. The cutting forces model for helical end-mills is based on the oblique cutting theory and the geometric relations of the ball-end milling process. The helical flutes are divided into small differential oblique cutting edge segments. According to the transformation relationship between the local and global coordinate system of the cutter, the differential cutting force of cutting element is obtained by two coordinate conversions from the orthogonal cutting force. The total cutting force of helical ball-end milling is the sum of the cutting force in whole cutting field of the miller. As a result, the predicted cutting forces show an agreement with the values from the cutting experiments.

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Guo, Yu, Bin Lin, and Weiqiang Wang. "Modeling of Cutting Forces with a Serrated End Mill." Mathematical Problems in Engineering 2019 (March 11, 2019): 1–13. http://dx.doi.org/10.1155/2019/1796926.

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The paper presents a mechanistic cutting force model of serrated end mill to predict cutting forces. Geometric model of serrated end mill is established, which covers variable helix end mill geometries. In this model, the serration of helical cutting flutes is expressed spatially and the wave of serration is defined to be a sine wave. The spatial vector is applied to define chip thickness so as to enhance the spatial expressiveness of the model, which is perpendicular to the curvature of each flute. Each helical flute is scatted into a series of infinitesimal cutting edges. The infinitesimal cutting forces depend on three cutting force coefficients and three edge force coefficients in the tangential, radial, and axial directions at every cutting element. By integrating the infinitesimal cutting forces along each cutting edge, the milling forces with serrated end mill can be predicted. The model feasibility of the serrated end mill is verified by comparing the predicted and measured cutting forces. Moreover, the model is also verified such that it can also predict cutting forces with other types of end mills, such as variable helix serrated end mill, variable helix end mill, and regular end mill.

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Zheng, Li, and S. Y. Liang. "Identification of Cutter Axis Tilt in End Milling." Journal of Manufacturing Science and Engineering 119, no. 2 (1997): 178–85. http://dx.doi.org/10.1115/1.2831093.

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The scope of the paper is to discuss the identification of cutter axis tilt in end milling process via cutting force analysis. Cutter axis tilt redistributes the chip load among flutes thereby generating minor frequency components of cutting forces. These minor components can be utilized to infer the tilt geometry during the cutting action. This study involved the mathematical representation of chip thickness variation due to tilt, the modeling of local forces in relation to instantaneous chip thickness, the formulation of total cutting forces through convolution integration in the angle domain, the derivation of dynamic force components in the frequency domain, and the solution for tilt geometry from the dynamic cutting forces. Results show that the tilt magnitude and orientation can be estimated given the dynamic cutting force components along with the tool/work geometry, cutting parameters, and machining configuration. Numerical simulation results confirmed the validity of the angle domain convolution approach, and the end milling experimental data agreed with the analytical model.

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Gomi, Nobu, N. Ishii, R. Hozumi, and H. Kumehara. "End-Mill Evaluation by Measurement of Cutting Force." Materials Science Forum 675-677 (February 2011): 681–84. http://dx.doi.org/10.4028/www.scientific.net/msf.675-677.681.

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Evaluation of manufacturing process in milling by direct measurement of cutting force is considered to be effective comparing to indirect measurement of electricity. This paper proposed a new evaluation method of end-mills by the direct measurement of cutting force. Cutting forces were precisely obtained by a 3-component dynamometer during end milling. Each flute cutting forces was evaluated for two types of end-mills (non wear-out, wear-out) by wave patterns of cutting force. A distinctive difference in the two types of end-mills has been clearly seen. The effectiveness of the proposed evaluation method has been clarified.

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Yang, Liuqing, Richard E. DeVor, and Shiv G. Kapoor. "Analysis of Force Shape Characteristics and Detection of Depth-of-Cut Variations in End Milling." Journal of Manufacturing Science and Engineering 127, no. 3 (2004): 454–62. http://dx.doi.org/10.1115/1.1947207.

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This paper proposes an analytical approach to detect depth-of-cut variations based on the cutting-force shape characteristics in end milling. Cutting forces of a single-flute end mill are analyzed and classified into three types according to their shape characteristics. Cutting forces of a multiple-flute end mill are then classified by considering both the cutting types of the corresponding single-flute end mill and the degree of overlap of successive flutes in the cut. Force indices are extracted from the cutting forces and depth-of-cut variations are detected based on the changes of the force shape characteristics via the force indices in an end-milling process. The detection methodology is validated through cutting experiments.

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Pan, Wencheng, Songlin Ding, and John Mo. "The prediction of cutting force in end milling titanium alloy (Ti6Al4V) with polycrystalline diamond tools." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 231, no. 1 (2016): 3–14. http://dx.doi.org/10.1177/0954405415581299.

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Cutting force coefficients were conventionally described as the power function of instantaneous uncut chip thickness. However, it was found that the changes in the three controllable machining parameters (cutting speed, feed and axial cutting depth) could significantly affect the values of cutting coefficients. An improved cutting force model was developed in this article based on the experimental investigation of end milling titanium alloy (Ti6Al4V) with polycrystalline diamond tools. The relationships between machining parameters and cutting force are established based on the introduction of the new cutting coefficients. By integrating the effects of varying cutting parameters in the prediction model, cutting forces and the fluctuation of cutting force in each milling cycle were calculated. Validation experiments show that the predicted peak values of cutting forces highly match the experimental results; the accuracy of the model is up to 90% in predicting instantaneous cutting forces.

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Teramoto, Koji, Takahiro Kunishima, and Hiroki Matsumoto. "Analysis of Cutting Force in Elastomer End-Milling." International Journal of Automation Technology 11, no. 6 (2017): 958–63. http://dx.doi.org/10.20965/ijat.2017.p0958.

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Elastomer end-milling is attracting attention for its role in the small-lot production of elastomeric parts. In order to apply end-milling to the production of elastomeric parts, it is important that the workpiece be held stably to avoid deformation. To evaluate the stability of workholding, it is necessary to predict cutting forces in elastomer end-milling. Cutting force prediction for metal workpiece end-milling has been investigated for many years, and many process models for end-milling have been proposed. However, the applicability of these models to elastomer end-milling has not been discussed. In this paper, the characteristics of the cutting force in elastomer end-milling are evaluated experimentally. A standard cutting force model and its parameter identification method are introduced. By using this cutting force model, measured cutting forces are compared against the calculated results. The comparison makes it clear that the standard cutting force model for metal end-milling can be applied to down milling for a rough evaluation.

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An, Zeng Hui, Xiu Li Fu, Ya Nan Pan, and Ai Jun Tang. "An Experiment-Based Investigation on Characteristic and Model of Milling Forces during End-Milling Aluminum Alloy." Applied Mechanics and Materials 494-495 (February 2014): 602–5. http://dx.doi.org/10.4028/www.scientific.net/amm.494-495.602.

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Cutting forces is one of the important physical phenomena in metal cutting process. It directly affects the surface quality of machining, tool life and cutting stability. The orthogonal experiments of cutting forces and influence factors with indexable and solid end mill were accomplished and the predictive model of milling force was established during high speed end milling 7050-T7451 aluminum alloy. The paper makes research mainly on the influence which the cutting speed, cutting depth and feed have on the cutting force. The experimental results of single factor showed that the cutting forces increase earlier and drop later with the increase of cutting speed, and the cutting speed of inflexion for 7050-T7451 is 1100m/min. As axial cutting depth, radial cutting depth and feed rate increase, the cutting force grows in different degree. The cutting force is particularly sensitive to axial cutting depth and slightly to the radial cutting depth.

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Tukora, Balázs, and Tibor Szalay. "Real-Time Cutting Force Prediction and Cutting Force Coefficient Determination during Machining Processes." Advanced Materials Research 223 (April 2011): 85–92. http://dx.doi.org/10.4028/www.scientific.net/amr.223.85.

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In this paper a new method for instantaneous cutting force prediction is presented, in case of sculptured surface milling. The method is executed in a highly parallel manner by the general purpose graphics processing unit (GPGPU). As opposed to the accustomed way, the geometric information of the work piece-cutter touching area is gained directly from the multi-dexel representation of the work-piece, which lets us compute the forces in real-time. Furthermore a new procedure is introduced for the determination of the cutting force coefficients on the basis of measured instantaneous or average orthogonal cutting forces. This method can determine the shear and ploughing coefficients even while the cutting geometry is continuously altering, e.g. in the course of multi-axis machining. In this way the cutting forces can be predicted during the machining process without a priori knowledge of the coefficients. The proposed methods are detailed and verified in case of ball-end milling, but the model also enables the applying of general-end cutters.

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Yuan, Yan Jie, Xiu Bing Jing, Huai Zhong Li, and Jun Wang. "An Experimental Investigation of Cutting Forces in Micro End-Milling Process." Key Engineering Materials 693 (May 2016): 710–17. http://dx.doi.org/10.4028/www.scientific.net/kem.693.710.

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This paper presents an experimental study of cutting forces during micro end-milling of brass. The influences of cutting speed and feed per tooth on cutting forces have been researched. The results show that the resultant force Fr and feed force Fx significantly increase with increasing the feed per tooth. The resultant force Fr, feed force Fxand normal force Fy increase with increasing cutting speed. The specific shear energy is also investigated. It is observed that the specific shear energy increases greatly with decreasing the feed per tooth when the feed per tooth is less than minimum chip thickness.

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Zheng, C. M., and J. J. Junz Wang. "Estimation of in-process cutting constants in ball-end milling." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 217, no. 1 (2003): 45–56. http://dx.doi.org/10.1243/095440503762502279.

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Two methods are presented for the estimation of tangential, radial and axial cutting coefficients for the shearing and ploughing mechanisms from a single set of cutting forces in ball-end milling. These estimation methods are based upon the invertibility of the analytical milling force model, which considers both the shearing and the ploughing mechanisms by incorporating their respective cutting constants in the local force model. The periodic milling forces are established as the convolution integral of the differential local cutting forces and their Fourier coefficients are derived and expressed in a matrix expression as a linear function of the unknown cutting constants in terms of cutting conditions and cutter geometry. This linear expression thus leads to a systematic formulation of the estimation methods allowing the six unknown cutting constants to be determined from the measured milling forces. The first method uses the first harmonic forces as the source signal while the second method extracts the six cutting constants from the average force as well as the first harmonics. Limitations of both estimation methods are discussed. The consistency and accuracy of the estimated cutting constants are confirmed by the experimental results.

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Dikshit, Mithilesh K., Asit Baran Puri, Atanu Maity, and Amit Jyoti Banarjee. "Determining cutting force coefficients from instantaneous cutting forces in ball end milling." International Journal of Machining and Machinability of Materials 18, no. 5/6 (2016): 552. http://dx.doi.org/10.1504/ijmmm.2016.078984.

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Karunasawat, Keerati, and Somkiat Tangjitsitcharoen. "Surface Roughness Prediction in Ball-End Milling Process for Aluminum by Using Air Blow Cutting." Advanced Materials Research 418-420 (December 2011): 1428–34. http://dx.doi.org/10.4028/www.scientific.net/amr.418-420.1428.

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The objective of this research is to develop the surface roughness and cutting force models by using the air blow cutting of the aluminum in the ball-end milling process. The air blow cutting proposed in order to reduce the use of the cutting fluid. The surface roughness and cuttting force models are proposed in the exponential forms which consist of the cutting speed, the feed rate, the depth of cut, the tool diameter, and the air blow pressure. The coefficients of the surface roughness and cutting force models are calculated by utilizing the multiple regression with the least squared method at 95% significant level. The effects of cutting parameters on the cutting force are investigated and measured to analyze the relation between the surface roughness and the cutting conditions. The experimentally obtained results showed that the cutting force has the same trend with the surface roughness. The surface plots are constructed to determine the optimum cutting condition referring to the minimum surface roughness.

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Kao, Yung-Chou, Nhu-Tung Nguyen, Mau-Sheng Chen, and Shyh-Chour Huang. "A combination method of the theory and experiment in determination of cutting force coefficients in ball-end mill processes." Journal of Computational Design and Engineering 2, no. 4 (2015): 233–47. http://dx.doi.org/10.1016/j.jcde.2015.06.005.

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Abstract In this paper, the cutting force calculation of ball-end mill processing was modeled mathematically. All derivations of cutting forces were directly based on the tangential, radial, and axial cutting force components. In the developed mathematical model of cutting forces, the relationship of average cutting force and the feed per flute was characterized as a linear function. The cutting force coefficient model was formulated by a function of average cutting force and other parameters such as cutter geometry, cutting conditions, and so on. An experimental method was proposed based on the stable milling condition to estimate the cutting force coefficients for ball-end mill. This method could be applied for each pair of tool and workpiece. The developed cutting force model has been successfully verified experimentally with very promising results. Highlights By investigation of the stable cutting conditions in milling process, the linear function of average cutting force and feed per flute was successfully verified. A combined theoretical-experimental method was proposed with an effective model for the determination of cutting force coefficients in ball-end mill process.

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NARITA, Hirohisa. "3291 An approach of cutting coefficients determination for cutting force model of ball end mills." Proceedings of International Conference on Leading Edge Manufacturing in 21st century : LEM21 2011.6 (2011): _3291–1_—_3291–4_. http://dx.doi.org/10.1299/jsmelem.2011.6._3291-1_.

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Kang, Yong Gang, Zhong Qi Wang, Wen Ming Lou, and Cheng Yu Jiang. "Study of the Classification of Cutting Forces and the Build of Accurate Milling Force Model in End Milling." Materials Science Forum 532-533 (December 2006): 636–39. http://dx.doi.org/10.4028/www.scientific.net/msf.532-533.636.

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A new approach is proposed to model the milling force based on the cutting force shape characteristics in end milling. The relationship between the cutting force shape characteristics and the cutting depths is analyzed and milling forces are classified into 10 types according to the combination of cutting depths. Further, force indices are extracted and then the real cutting depths are detected based on the changes of force curve characteristics via the force indices in end milling process. Then, bring forward a method of modeling cutting force based on the different types, and the use of real cutting depth makes the model to be more accurately. More important, experiments designed on the classification of milling forces strengthen the pertinence, and makes the experiment data more reliable. The approach is validated through experiments on aluminum alloy 7050-T7451.

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Li, An Hai, Jun Zhao, He Lin Pan, and Zhao Chao Gong. "Modeling and Simulation of Cutting Forces in Side Milling." Key Engineering Materials 693 (May 2016): 843–49. http://dx.doi.org/10.4028/www.scientific.net/kem.693.843.

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In order to acquire high machining quality and minimum machining time, cutting forces are usually modeled to understand the milling process, simulate or predict cutting forces, and optimize the machining parameters. In this paper, side milling tests were conducted on superalloy Inconel 718 with a solid carbide end mill, and the cutting forces vs. cutting time were measured. The average cutting forces were extracted from the measured instantaneous cutting forces under different feed rates of experiments, and the components of the shear forces and edge forces were determined by using the linear regression of the experimental data. The cutting force coefficients, including shear force coefficients and edge force coefficients, were identified. In addition, the algorithms of the mathematical model were implemented in Matlab. The predicted cutting forces were in good agreement with the experimentally measured forces, and the validation of the cutting force model was demonstrated.

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NAMAZI, HAMIDREZA, ALI AKHAVAN FARID, and TECK SENG CHANG. "FRACTAL-BASED ANALYSIS OF THE VARIATIONS OF CUTTING FORCES ALONG DIFFERENT AXES IN END MILLING OPERATION." Fractals 26, no. 06 (2018): 1850089. http://dx.doi.org/10.1142/s0218348x18500895.

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Analysis of cutting forces in machining operation is an important issue. The cutting force changes randomly in milling operation where it makes a signal by plotting over time span. An important type of analysis belongs to the study of how cutting forces change along different axes. Since cutting force has fractal characteristics, in this paper for the first time we analyze the variations of complexity of cutting force signal along different axes using fractal theory. For this purpose, we consider two cutting depths and do milling operation in dry and wet machining conditions. The obtained cutting force time series was analyzed by computing the fractal dimension. The result showed that in both wet and dry machining conditions, the feed force (along [Formula: see text]-axis) has greater fractal dimension than radial force (along [Formula: see text]-axis). In addition, the radial force (along [Formula: see text]-axis) has greater fractal dimension than thrust force (along [Formula: see text]-axis). The method of analysis that was used in this research can be applied to other machining operations to study the variations of fractal structure of cutting force signal along different axes.

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Zheng, Li, Steven Y. Liang, and Shreyes N. Melkote. "Angle Domain Analytical Model for End Milling Forces." Journal of Manufacturing Science and Engineering 120, no. 2 (1998): 252–58. http://dx.doi.org/10.1115/1.2830121.

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This paper presents the development of an explicit expression of cutting force wave forms in end milling with helical multi-flute cutters. From the relationship of elemental cutting forces and chip load, the net cutting forces are analytically formulated based on the integration of elemental cutting forces in the feed, cross feed, and axial directions. This formulation leads to a solution of force waveforms as algebraic functions of tool geometry, machining parameters, cutting configuration, and work piece material properties. The closed-form nature of the resulting model facilitates force estimation and process optimization without resorting to numerical iterations. The theoretical error of prediction due to the truncation of higher frequency terms is analyzed. It provides a guideline for choosing the model size for given error tolerance. It also offers an understanding of upper bound of prediction error for a known number of approximating terms used in the model. In the paper end milling experimental results were examined over a range of conditions to verify the analytical model in the context of waveform, power spectrum, and model size effect.

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NAMAZI, HAMIDREZA, ALI AKHAVAN FARID, and CHANG TECK SENG. "FRACTAL-BASED ANALYSIS OF THE INFLUENCE OF CUTTING DEPTH ON COMPLEX STRUCTURE OF CUTTING FORCES IN ROUGH END MILLING." Fractals 26, no. 05 (2018): 1850068. http://dx.doi.org/10.1142/s0218348x18500688.

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Analysis of the cutting forces during machining operations is an important issue. The rough end mill with the serrated profile is broadly used for reduction of cutting forces during milling operation. Since cutting force changes in random behavior during end milling, in this paper we employ fractal theory to analyze the complex structure of cutting force signal. For this purpose, we investigated the influence of variations of cutting depth on variations of fractal structure of cutting forces in wet and dry machining conditions. The results of our analysis showed the variations of fractal structure of cutting forces between different cutting depths, in wet and dry conditions. The employed methodology in this research is not limited to rough end milling and can potentially be applied to other types of machining operations, where the variations of cutting forces is an important issue.

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Feng, Hsi-Yung, and Ning Su. "A Mechanistic Cutting Force Model for 3D Ball-end Milling." Journal of Manufacturing Science and Engineering 123, no. 1 (2000): 23–29. http://dx.doi.org/10.1115/1.1334864.

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This paper presents an improved mechanistic cutting force model for the ball-end milling process. The objective is to accurately model the cutting forces for nonhorizontal and cross-feed cutter movements in 3D finishing ball-end milling. Main features of the model include: (1) a robust cut geometry identification method to establish the complicated engaged area on the cutter; (2) a generalized algorithm to determine the undeformed chip thickness for each engaged cutting edge element; and (3) a comprehensive empirical chip-force relationship to characterize nonhorizontal cutting mechanics. Experimental results have shown that the present model gives excellent predictions of cutting forces in 3D ball-end milling.

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O’Connor, Alex, and Mamidala Ramulu. "A Mechanistic Model for End Milling Cutting Forces in Brittle Porous Material." Advanced Materials Research 1082 (December 2014): 143–51. http://dx.doi.org/10.4028/www.scientific.net/amr.1082.143.

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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.

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Junz Wang, J. J., and C. M. Zheng. "Online Identification of Shearing and Plowing Constants in End Milling." Journal of Manufacturing Science and Engineering 125, no. 1 (2003): 57–64. http://dx.doi.org/10.1115/1.1536931.

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Online methods for the identification of shearing and plowing cutting constants from forces in a single milling operation are presented. By virtue of the analytical nature of the milling force model in the frequency domain, the shearing and plowing constants are expressed, in a linear closed-form equation, in terms of cutter geometry, cutting depths and the Fourier coefficients of the milling forces. Two methods are presented to identify these cutting constants. The first method uses only the first harmonic components of the milling forces, and the second method utilizes the average forces as well as the ratio of the first harmonic forces. Limitations on the cutting conditions for each identification method are discussed. The accuracy and consistency of these two methods in extracting the shearing and plowing constants from a single set of force measurements are verified through simulation and milling experiments.

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Jiang, Bin, Min Li Zheng, Shu Cai Yang, and M. Fu. "Research on High Speed Ball-End Milling Forces." Key Engineering Materials 315-316 (July 2006): 25–29. http://dx.doi.org/10.4028/www.scientific.net/kem.315-316.25.

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Based on the experiment of high speed milling ball-end milling forces, the model of ball-end milling force is established for high speed machining complex surface by differential method, and research on the principle of high speed ball-end milling force. Results show that the parameters of cutting layer are subjected to varying curvature of complex surface, and place in the unstable state, cutting force decreases as the curvature and the inclination angle increase. By means of lessening cutting speed’s grads and adjusting the inclination angle and the path interval of cutter to the variety of curvature, cutting force and its fluctuation can be depressed availably; the process of high speed ball-end milling can be obviously improved.

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NAMAZI, HAMIDREZA, ALI AKHAVAN FARID, and CHANG TECK SENG. "COMPLEXITY-BASED ANALYSIS OF THE INFLUENCE OF TOOL GEOMETRY ON CUTTING FORCES IN ROUGH END MILLING." Fractals 26, no. 05 (2018): 1850078. http://dx.doi.org/10.1142/s0218348x18500780.

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It is known that geometry of cutting tool affects the cutting forces in machining operations. In addition, the value of cutting forces changes during machining operations and creates a chaotic time series (signal). In this paper, we analyze the variations of the complex structure of cutting force signal in rough end milling operation using fractal theory. In fact, we analyze the variations of cutting force signal due to variations of tool geometry (square end mill versus serrated end mill). In case of each type of end mill, we did the machining operation in wet and dry conditions. Based on the results, the fractal structure of cutting force signal changes based on the type of milling tool. We also did the complexity analysis using approximate entropy to check the variations of the complexity of cutting force signal, where the similar behavior of variations between different conditions was obtained. The method of analysis that was used in this research can be applied to other machining operations to study the influence of different machining parameters on variations of fractal structure of cutting force.

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Pu, Xionig Ying, Wei Jun Liu, and Ji Bin Zhao. "Model of End Milling Force Based on Undeformed Chip Surface with NURBS in Peripheral Milling." Applied Mechanics and Materials 33 (October 2010): 356–62. http://dx.doi.org/10.4028/www.scientific.net/amm.33.356.

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A new cutting force model for peripheral milling is presented based-on a developed algorithm for instantaneous undeformed chip surface with NURBS. To decrease the number of the differential element, the contact cutting edges of end-milling cutter with the part and the chip thickness curve are represented by NURBS helix, and the instantaneous undeformed chip is constructed as a ruled surface with the two curves. The cutting force generated by the edge contact length and the uncut chip area. Using the cutting coefficients from Budak[1] , the cutting-force model verified by simulation. The simulation results indicate that new cutting-force model predict the cutting forces in peripheral milling accurately.

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Li, Zhen, and Bing Yan. "Ball-End Cutter Machining Process Analysis in Five-Axis Milling." Applied Mechanics and Materials 34-35 (October 2010): 903–8. http://dx.doi.org/10.4028/www.scientific.net/amm.34-35.903.

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In this paper, the three dimensional geometrical analysis is depicted with the interacting relations among cutting edge, undeformed chip and shear zone along cutting direction, and a general geometrical model of five-axis machining curve surface in ball-end milling is presented. A general force model is derived, and the three dimensional cutting forces are predicted. The influences of different angle of the centerline of the cutter to the cutting forces are considered. The three dimensional cutting forces are applied to construct and analysis the structural vibratory model of the system.

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Feng, Zhixin, Meng Liu, and Guohe Li. "Identification of Polynomial Cutting Coefficients for a Dual-Mechanism Ball-end Milling Force Model." Recent Patents on Engineering 13, no. 3 (2019): 232–40. http://dx.doi.org/10.2174/1872212112666180629142036.

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Background: Calibration of cutting coefficients is the key content in modeling a mechanistic cutting force model. Generally, in modeling cutting force for ball end milling, the tangent, radial and binormal cutting force coefficients are each considered as a polynomial, respectively. This fact is due to the dependency between the cutting force coefficients and the cutting edge inclination angle which is variable in ball-end mills. Objective: This paper presents an approach to determine the polynomial cutting force coefficients. Methods: In this approach, the cutting force coefficients are expressed as explicit linear equations about the average slotting forces. After analysis of the least square regression method which is utilized in the cutting coefficients evaluation, the principle of cutting parameters choice in calibration experiment and the relationship between the order of polynomial and the number of experiments are presented. Besides, a lot of patents on identification of polynomial cutting coefficients for milling force model were studied. Results: Finally, a series of semi-slotting verification cutting tests were arranged, the measured force agrees well with the predicted force, which demonstrates the effectiveness of this approach. Conclusion: Based on the calibration method proposed in this paper, the cutting coefficients can be determined through (m+2) slotting experiments for m-degree shearing coefficients polynomial theoretically.

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Kang, Renke, Jinting Liu, Zhigang Dong, Feifei Zheng, Yan Bao, and Jiadong Duan. "An Improved Cutting Force Model for Ultrasonically Assisted Grinding of Hard and Brittle Materials." Applied Sciences 11, no. 9 (2021): 3888. http://dx.doi.org/10.3390/app11093888.

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Cutting force is one of the most important factors in the ultrasonically assisted grinding (UAG) of hard and brittle materials. Many theoretical and experimental studies show that UAG can effectively reduce cutting forces. The existing models for UAG mostly assume an ideal grinding wheel with abrasives in both the end and lateral faces to accomplish material removal, whereas the important role of the transition fillet surface is ignored. In this study, a theoretical cutting force model is presented to predict cutting forces with the consideration of the diamond abrasives in the end face, the lateral face, and the transition fillet surface of the grinding tool. This study analyzed and calculated the vibration amplitudes and the cutting forces in both the normal and tangential directions. It discusses the influences of the input parameters (rotation speed, feed rate, amplitude, depth and radius of transition fillet) on cutting forces. The study demonstrates that the fillet radius is an important factor affecting the grinding force. With an increase in fillet radius from 0.2 to 1.2 mm, the grinding force increases by 139.6% in the axial direction and decreases by 70% in the feed direction. The error of the proposed cutting force model is 10.3%, and the experimental results verify the correctness of the force model.

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Huang, Hui, Chong Fa Huang, and Xi Peng Xu. "Force Characteristics in Drilling of Engineering Ceramic with a Brazed Diamond Tool." Key Engineering Materials 359-360 (November 2007): 153–57. http://dx.doi.org/10.4028/www.scientific.net/kem.359-360.153.

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An experimental study was carried out to investigate the force in drilling of engineering ceramic with a brazed diamond tool. The drilling forces and protrusion heights of diamond grains were measured. The results showed that the variation of cutting forces, increasing with the cutting time, was divided into three phases for a drilled hole. For each phase, the variation of cutting forces was different. The drilling forces also increased with the numbers of drilled holes due to the wear of diamond grits. The distance values of the cutting force between the end of first phase and the end of second phase approximately kept constant.

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Abebe, Girma Seife, and Ping Liu. "Experimental Study of End Milling Force on Manganese Steel." Advanced Materials Research 718-720 (July 2013): 239–43. http://dx.doi.org/10.4028/www.scientific.net/amr.718-720.239.

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Cutting force is a key factor influencing the machining deformation of weak rigidity work pieces. In order to reduce the machining deformation and improve the process precision and the surface quality, it is necessary to study the factors influencing the cutting force and build the regression model of cutting forces. This paper discusses the development of the first and second order models for predicting the cutting force produced in end-milling operation of modified manganese steel. The first and second order cutting force equations are developed using the response surface methodology (RSM) to study the effect of four input cutting parameters (cutting speed, feed rate, radial depth and axial depth of cut) on cutting force. The separate effect of individual input factors and the interaction between these factors are also investigated in this study. The received second order equation shows, based on the variance analysis, that the most influential input parameter was the feed rate followed by axial depth, and radial depth of cut. It was found that the interaction of feed with axial depth was extremely strong. In addition, the interactions of feed with radial depth; and feed rate with radial depth of cut were observed to be quite significant. The predictive models in this study are believed to produce values of the longitudinal component of the cutting force close to those readings recorded experimentally with a 95% confident interval.

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Zhang, Xuewei, Tianbiao Yu, and Wanshan Wang. "Dynamic cutting force prediction for micro end milling considering tool vibrations and run-out." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 233, no. 7 (2018): 2248–61. http://dx.doi.org/10.1177/0954406218781966.

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An accurate prediction of cutting forces in the micro end milling, which is affected by many factors, is the basis for increasing the machining productivity and selecting optimal cutting parameters. This paper develops a dynamic cutting force model in the micro end milling taking into account tool vibrations and run-out. The influence of tool run-out is integrated with the trochoidal trajectory of tooth and the size effect of cutting edge radius into the static undeformed chip thickness. Meanwhile, the real-time tool vibrations are obtained from differential motion equations with the measured modal parameters, in which the process damping effect is superposed as feedback on the undeformed chip thickness. The proposed dynamic cutting force model has been experimentally validated in the micro end milling process of the Al6061 workpiece. The tool run-out parameters and cutting forces coefficients can be identified on the basis of the measured cutting forces. Compared with the traditional model without tool vibrations and run-out, the predicted and measured cutting forces in the micro end milling process show closer agreement when considering tool vibrations and run-out.

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Tangjitsitcharoen, Somkiat, Prae Thesniyom, and Suthas Ratanakuakangwan. "A wavelet approach to predict surface roughness in ball-end milling." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 231, no. 14 (2015): 2468–78. http://dx.doi.org/10.1177/0954405415605951.

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This research proposed an advance in the prediction of the in-process surface roughness during the ball-end milling process by utilizing the wavelet transform to monitor and decompose the dynamic cutting forces. The chatter detection system has been adopted from the previous research of the author to avoid the chatter first, and hence, the dynamic cutting force ratio is introduced to predict the in-process surface roughness during the normal cutting by taking the ratio of the decomposed dynamic cutting force in X axis to that in Z axis. The Daubechies wavelet transform is employed in this research to analyze the in-process surface roughness. The experimentally obtained results showed that the surface roughness frequency occurred at the same level of the decomposed dynamic cutting forces although the cutting conditions are changed. It is understood that the in-process surface roughness can be predicted effectively under various cutting conditions referring to the proposed monitoring system.

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Niu, Zhichao, and Kai Cheng. "Improved dynamic cutting force modelling in micro milling of metal matrix composites part II: Experimental validation and prediction." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 234, no. 8 (2019): 1500–1515. http://dx.doi.org/10.1177/0954406219893725.

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The effects of cutting dynamics and the particles' size and density cannot be ignored in micro milling of metal matrix composites. This article presents the improved dynamic cutting force modelling for micro milling of metal matrix composites based on the previous analytical model. This comprehensive improved cutting force model, taking the influence of the tool run-out, actual chip thickness and resultant tool tip trajectory into account, is evaluated and validated through well-designed machining trials. A series of side milling experiments using straight flutes polycrystalline diamond end mills are carried out on the metal matrix composite workpiece under various cutting conditions. Subsequently, the measured cutting forces are compensated by a Kalman filter to achieve the accurate cutting forces. These are further compared with the predicted cutting forces to validate the proposed dynamic cutting force model. The experimental results indicate that the predicted and measured cutting forces in micro milling of metal matrix composites are in good agreement.

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Reddy, Moola Mohan, Alexander Gorin, and Khaled A. Abou-El-Hossein. "Development of Cutting Force Model of Aluminum Nitride Ceramic Processed by Micro End Milling." Applied Mechanics and Materials 87 (August 2011): 223–29. http://dx.doi.org/10.4028/www.scientific.net/amm.87.223.

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Advanced ceramics are difficult to do machining due to brittle nature. High cutting forces will generate in the machining, which will affect the surface integrity of final product. Selection of proper machining parameters is important to obtain less cutting force. The present work deals with the study and development of a cutting force prediction model in end milling operation of Aluminum Nitride ceramic. The cutting force equation developed using Response Surface Methodology (RSM) to analyze the effect of Spindle speed, feed rate and axial depth of cut. The cutting tests were carried under dry condition using two flute square end micro grain carbide end mills.

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Ganapathy, B. K., and I. S. Jawahir. "Modeling the Chip-Work Contact Force for Chip Breaking in Orthogonal Machining With a Flat-Faced Tool." Journal of Manufacturing Science and Engineering 120, no. 1 (1998): 49–56. http://dx.doi.org/10.1115/1.2830110.

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The present tendency towards increased automation of metal cutting operations has resulted in a need to develop a model for the chip breaking process. Conventional cutting force models do not have any provision for the study of chip breaking since they assume a continuous mode of chip formation, where the contact action of the free-end of the chip is ignored in all analyses. The new cutting force model proposed in this work incorporates the contact force developed due to the free-end of the chip touching the workpiece, and is applicable to the study of two-dimensional chip breaking in orthogonal machining. Orthogonal cutting tests were performed to obtain two-dimensional chip breaking. The experimentally measured cutting forces show a good correlation with the estimated cutting forces using the model. Results show that the forces acting on the chip vary within a chip breaking cycle and help identify the chip breaking event.

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Liu, Wan Zhu, Qiang Liu, Ge Gao, and Xue Yan. "The Effects of Curvature Radius on Cutting Force and Stability during End Milling." Advanced Materials Research 314-316 (August 2011): 1721–26. http://dx.doi.org/10.4028/www.scientific.net/amr.314-316.1721.

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The influence of radius ratio of cutting point and cutter on cutting force and stability during end milling process is presented in this paper. To derive motion equations, a 2 DOF mechanical model of end milling considering both regenerative and self-excited effects was established. Different ratio values during three milling conditions were analyzed. Cutting forces as well as stability under different radius ratios by changing curvature radius and cutter radius were elaborated respectively. The results show that when other parameters are set fixed, cutter with relative large radius has smaller cutting force and larger stable range. Cutters with same radius will overlap on cutting force when radius ratio is large enough even under different milling conditions. The proposed analysis on cutting force and stability can be used to determine the optimal parameters, such as cutter radius and spindle speed etc. to improve the accuracy and productivity.

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Sui, Xiu Lin, and Ping Zhang. "Modeling and Simulation of Milling Forces for Ball-End Cutter with Considering Comprehensive Factors." Applied Mechanics and Materials 121-126 (October 2011): 2098–104. http://dx.doi.org/10.4028/www.scientific.net/amm.121-126.2098.

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In this paper, influence mechanism of variously physical factors for milling force in any feed direction is studied during the milling process. Firstly, the effects of spindle eccentricity, cutter deflection and cutter vibration for the instantaneously undeformed cutting thickness are analyzed, and the mathematical expressions of chip thickness is set up. Then,on this basis of cutting force and chip load, the milling force model of ball-end mill with considering integrated physical factors is established though the differential method, and a simulation system for prediction of milling forces during the milling process is developed. This milling force model is verified through simulation and analysis of milling forces.

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Shan, Chen Wei, Ying Zhao, and Dong Peng Cui. "Experimental Study on Ball-End Milling of C/C Composite." Advanced Materials Research 650 (January 2013): 139–44. http://dx.doi.org/10.4028/www.scientific.net/amr.650.139.

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Along with the development of high speed machining technology, the ball end milling cutter’s application is more and more widely. An influence of four control parameters, namely feed, cutting depth, spindle speed and cutting width, on cutting forces is investigated. This paper focuses on experimental research of milling process of carbon fiber reinforced carbon matrix composite (C/C composite). The milling force prediction model for milling of composite using the carbide ball-end tools is built by orthogonal experiment. The experiment results show that : the reliability of the this prediction model is quite high, and the effect of milling speed on milling force is not very obvious, but the milling force increases with the increment of feed per tooth, milling depth and milling width. Using this information, a new prediction model for the milling forces is proposed that can be used for C/C composite milling.

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Ashaari Kiprawi, Mohammad, Abdullah Yassin, Syed Tarmizi Syed Shazali, M. Shahidul Islam, and Mohd Azrin Mohd Said. "Assessment of Cutting Profile of AISI 1095 by Using Infrared Radiation Approach." International Journal of Engineering & Technology 7, no. 3.18 (2018): 79. http://dx.doi.org/10.14419/ijet.v7i3.18.16680.

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This research paper determines the relationship between cutting edge temperature, depth of cut, cutting speed, cutting forces and flank wear. The cutting edge temperature is determined by using a pyrometer consists of Indium Arsenide (InAs) and Indium Antimonide (InSb) photocells to detect infrared radiation that are released from cutting tool’s edge and cutting forces is measured by using a dynamometer. The machining process experiment is done by end milling the outer surface of AISI 1095 carbon steel. The output signal from the photocell and dynamometer is processed and recorded in the digital oscilloscope. Based on the results, the cutting edge temperature and cutting force increases as the depth of cut increases. Meanwhile, increasing cutting speed resulting in cutting edge temperature increases but decreasing in cutting force due to thermal deformation. Also, existence of progressive flank wear at cutting tool causes an increment in cutting edge temperature and cutting force proportionally.

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Latif, Afiff, Mohd Rasidi Ibrahim, Mohammad Sukri Mustapa, Noor Hakim Rafai, and Charles Prakash. "Effect of Variable Pitch on Cutting Temperature, Cutting Forces and Surface Roughness Using Nitico30 Cutting Tool when End Milling of Stainless Steel 316L." Materials Science Forum 909 (November 2017): 50–55. http://dx.doi.org/10.4028/www.scientific.net/msf.909.50.

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In this paper, a series of milling tests were carried out in order to identify the effects of variable pitch on cutting temperature, cutting force and surface roughness while end milling the stainless steel 316L using Nitico30 and conventional cutting tools. Slot-milling operations were conducted. The value of feed rate were choose between the range recommended by the manufactured for the both conventional and Nitico30 cutting tool. The effect of variable pitch on cutting temperature, cutting forces and surface roughness were discussed. Results showed that the cutting temperature increase with the increase of feed rate for both cutting tool. Further increasing the speed of feed rate, the cutting forces also gradually increase for both cutting tool. However, the comparison between both cutting tools, it was found that the cutting temperature, cutting force and surface roughness improve about 47.8%, 37.5% and 17.6% respectively for Nitico30 cutting tool.

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Yi, Yi Kai, Tie Qiang Gang, and Zhi Qiang Zhang. "Statistical Analysis of Dynamic Properties of Solid Carbide End Mill." Applied Mechanics and Materials 551 (May 2014): 37–41. http://dx.doi.org/10.4028/www.scientific.net/amm.551.37.

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By three-dimensional milling simulations of Aviation Aluminum 7050-T7451 with metal cutting finite element analysis software AdvantEdge FEM, milling force data was obtained and amplitude-frequency characteristics was achieved through Fourier transformation of milling forces. According to mathematical statistical analysis of milling force data, we illustrates that the high-speed milling is a multi-blade interrupted cutting process and the tool vibration is a random vibration. Correlation functions and power spectral density functions of milling force and displacement were calculated in terms of signal processing discipline.

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Hlaváč, Libor M., Damian Bańkowski, Daniel Krajcarz, Adam Štefek, Martin Tyč, and Piotr Młynarczyk. "Abrasive Waterjet (AWJ) Forces—Indicator of Cutting System Malfunction." Materials 14, no. 7 (2021): 1683. http://dx.doi.org/10.3390/ma14071683.

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Measurements enabling the online monitoring of the abrasive waterjet (AWJ) cutting process are still under development. This paper presents an experimental method which can be applicable for the evaluation of the AWJ cutting quality through the measurement of forces during the cutting process. The force measuring device developed and patented by our team has been used for measurement on several metal materials. The results show the dependence of the cutting to deformation force ratio on the relative traverse speed. Thus, the force data may help with a better understanding the interaction between the abrasive jet and the material, simultaneously impacting the improvement of both the theoretical and empirical models. The advanced models could substantially improve the selection of suitable parameters for AWJ cutting, milling or turning with the desired quality of product at the end of the process. Nevertheless, it is also presented that force measurements may detect some undesired effects, e.g., not fully penetrated material and/or some product distortions. In the case of a proper designing of the measuring device, the force measurement can be applied in the online monitoring of the cutting process and its continuous control.

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Yan, Xue, Hua Tao, D. H. Zhang, and B. H. Wu. "Cutting Force Prediction for Generalized Cornering Milling Process." Advanced Materials Research 188 (March 2011): 404–9. http://dx.doi.org/10.4028/www.scientific.net/amr.188.404.

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A developed method to predict the cutting forces in end milling of generalized corners is proposed in this paper. The cornering milling process is divided into a series of cutting segments with different cutting states. The mathematical model of the geometric relationship between cutter and the corner profile is established for each segment. Cutting forces is predicted by introducing the classical cutting force model. The computational results of cutting forces are in good agreement with experimental data.

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Hoon Ko, Jeong, and Dong-Woo Cho. "3D Ball-End Milling Force Model Using Instantaneous Cutting Force Coefficients." Journal of Manufacturing Science and Engineering 127, no. 1 (2005): 1–12. http://dx.doi.org/10.1115/1.1826077.

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Application of a ball-end milling process model to a CAD/CAM or CAPP system requires a generalized methodology to determine the cutting force coefficients for different cutting conditions. In this paper, we propose a mechanistic cutting force model for 3D ball-end milling using instantaneous cutting force coefficients that are independent of the cutting conditions. The uncut chip thickness model for three-dimensional machining considers cutter deflection and runout. An in-depth analysis of the characteristics of these cutting force coefficients, which can be determined from only a few test cuts, is provided. For more accurate cutting force predictions, the size effect is also modeled using the cutter edge length of the ball-end mill and is incorporated into the cutting force model. This method of estimating the 3D ball-end milling force coefficients has been tested experimentally for various cutting conditions.

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Journal articles on the topic 'Cutting force. eng'

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