Modeling of dynamic cutting forces and cutting characteristics based on the analyzed results of average force-feed rate relationship in milling processing

Nguyen, Nhu-Tung; Pham, Dong Van; Hoang, Dung Tien; Pham, Cuong Duc

doi:10.22061/jcarme.2021.8011.2070

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	Modeling of dynamic cutting forces and cutting characteristics based on the analyzed results of average force-feed rate relationship in milling processing
Journal of Computational & Applied Research in Mechanical Engineering (JCARME)
مقالات آماده انتشار، پذیرفته شده، انتشار آنلاین از تاریخ 12 آبان 1400 اصل مقاله (1.16 MB)
نوع مقاله: Research Paper
شناسه دیجیتال (DOI): 10.22061/jcarme.2021.8011.2070
نویسندگان
Nhu-Tung Nguyen ¹؛ Dong Van Pham²؛ Dung Tien Hoang³؛ Cuong Duc Pham ¹
¹HaUI Institute of Technology – HIT, Hanoi University of Industry, Vietnam
²Science and Technology Department, Hanoi University of Industry, Vietnam
³Faculty of Mechanical Engineering, Hanoi University of Industry
تاریخ دریافت: 31 فروردین 1400، تاریخ بازنگری: 21 مهر 1400، تاریخ پذیرش: 12 آبان 1400
چکیده
Cutting force coefficients (CFCs) are the most important factors in prediction of CFs (CFs) and other machining characteristics (MCs). This study was conducted to model the CFs and MCs in milling process based on the calculated values of CFCs. From the relationship of average values of CFs and feed rate, CFCs were determined and used to predict of dynamic CFs (DCFs) in flat milling process. In static models, the average values of CFs were presented as a linear regression of feed rate. The DCFs and other MCs were modeled depending on the cutting parameters, cutter geometry, CFCs, and structure parameters of machine-tool system. By performing the flat-milling process of gray cast iron GG25 using HSS-Co solid tool, the average CFs were modeled as the linear regression of feed rate with large determination coefficients (R2 > 93%). Besides, all CFCs of a pair of tool and workpiece for each cutting type were successfully determined based on the measured data of CFs from experimental process. Moreover, the proposed models of DCFs were successfully verified based on the compared results between the predicted CFs and measured CFs in several cutting tests with different cutting parameters. The proposed models of cutting force in this study were successfully used to predict the DCFs and several MCs in milling processes using flat milling tool. And can be used to design and develop the tool and machine in industrial manufacturing.
کلیدواژه‌ها
Dynamic cutting force؛ Average cutting forces؛ Cutting characteristics؛ Flat-milling process

مراجع
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Anselmetti, “Deviation of a machined surface in flank milling”, Int. J. Mach. Tools Manuf., Vol. 43, No. 2, pp.129-138, (2003). [12] A. Azeem, H. Y. Feng and L. Wang, “Simplified and efficient calibration of a mechanistic cutting force model for ball-end milling”, Int. J. Mach. Tools Manuf., Vol. 44, No. 2, pp. 291-298, (2004). [13] M. Wang, L. Gao and Y. Zheng, “An examination of the fundamental mechanics of cutting force coefficients”, Int. J. Mach. Tools Manuf., Vol. 78, pp. 1-7, (2014). [14] M. Wan, M. S. Lu, W. H. Zhang and Y. Yang, “A new ternary-mechanism model for the prediction of CFs in flat end milling”, Int. J. Mach. Tools Manuf., Vol. 57, pp. 34 – 45, (2012). [15] J. W. Dang, W. H. Zhang, Y. Yang and M. Wan, “Cutting force modeling for flat end milling including bottom edge cutting effect”, Int. J. Mach. Tools Manuf., Vol. 50, No. 11, pp. 986-997, (2010). [16] M. Wan, W. H. Zhang, J. W. Dang and Y. Yang, “A novel cutting force modeling method for cylindrical end mill”, Appl. Math. Modell., Vol. 34, No. 3, pp. 823-836, (2010). [17] A. Bhattacharyya, J. K. Schueller, B. P. Mann, J. C. Ziegert, T. L. Schmitz, F. J. Taylor and N. G. Fitz-Coy, “A closed form mechanistic cutting force model for helical peripheral milling of ductile metallic alloys”, Int. J. Mach. Tools Manuf., Vol. 50, No. 6, pp. 538-551, (2010). [18] Y. C. Kao, N. T. Nguyen, M. S. Chen and S. C. Huang, “A combination method of the theory and experiment in determination of cutting force coefficients in ball-end mill processes”, J. Comput. Des. Eng., Vol. 2, No. 4, pp. 233-247, (2015). [19] J. Gradišek, M. Kalveram and K. Weinert, “Mechanistic identification of specific force coefficients for a general end mill”, Int. J. Mach. Tools Manuf., Vol. 44, No. 4, pp. 401-414, (2004). [20] I. G. Euan, E, Ozturk and N. D. Sims. (2013). Modeling Static and Dynamic CFs and Vibrations for Inserted Ceramic Milling Tools. 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Nguyen, Modeling of Machining Dynamics: CFs and Machining Characteristics in Three-Axis Milling Processes. Science and technics publishing House, Hanoi, Vietnam, (2020).
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Modeling of dynamic cutting forces and cutting characteristics based on the analyzed results of average force-feed rate relationship in milling processing

[1] T. D. Hoang, N. T. Nguyen, D. Q. Tran and V. T. Nguyen, “CFs and Surface Roughness in Face-Milling of SKD61 Hard Steel”, Strojniski Vestnik/J. Mech. Eng., Vol. 65, No. 6, pp. 375-385, (2019).

[2] L. Imani, A. R. Henzaki, R. Hamzeloo and B. Davoodi, “Modeling and optimizing of cutting force and surface roughness in milling process of Inconel 738 using hybrid ANN and GA”, Proc. Inst. Mech. Eng., Part B: J. Eng. Manuf., Vol. 234, No.5, pp.920-932, (2020).

[3] M. E. Merchant, “Mechanics of the Metal Cutting Process. I. Orthogonal Cutting and a Type 2 Chip”, J. Appl. Phys., Vol. 16, No.5, pp.267-275, (1945).

[4] Y. Altintas, Manufacturing Automation: Metal cutting mechanics, machine tool vibrations, and CNC design. Cambridge University Press, 2nd ed, ISBN 978-1-00148-0, (2012).

[5] A. I. Fernández-Abia, J. Barreiro, L. N. L. de Lacalle and S. Martínez-Pellitero, “Behavior of austenitic stainless steels at high-speed turning using specific force coefficients”, Int. J. Adv. Manuf. Technol., Vol. 62, No. 5-8, pp. 505–515, (2012).

[6] N. Guibert, H. Paris and J. Rech, “A numerical simulator to predict the dynamical behavior of the self-vibratory drilling head”, Int. J. Mach. Tools Manuf., Vol. 48, No. 6, pp. 644–655, (2008).

[7] J. M. Lee, T. J. Je, D. S. Choi, S. W. Lee, D. Le and S. J. Kim, “Micro grooving simulation and optimization in the roughing stage", Int. J. Precis. Eng. Manuf., Vol. 11, No. 3, pp. 361-368, (2010).

[8] E. Budak, Y. Altintas and E. J. A. Armarego, “Prediction of milling force coefficients from orthogonal cutting data”, J. Manuf. Sci. Eng., Vol. 118, No. 2, pp. 216-224, (1996).

[9] X. P. Li and H. Z. Li, “Theoretical modelling of CFs in helical end milling with cutter run-out”, Int. J. Mech. Sci., Vol. 46, No. 9, pp.1399-1414, (2004).

[10] P. J. Cheng, J. T. Tsay and S. C. Lin, “A study on instantaneous cutting force coefficients in face milling”, Int. J. Mach. Tools Manuf., Vol. 37, No. 10, pp.1393-1408, (1997).

[11] A. Larue and B. Anselmetti, “Deviation of a machined surface in flank milling”, Int. J. Mach. Tools Manuf., Vol. 43, No. 2, pp.129-138, (2003).

[12] A. Azeem, H. Y. Feng and L. Wang, “Simplified and efficient calibration of a mechanistic cutting force model for ball-end milling”, Int. J. Mach. Tools Manuf., Vol. 44, No. 2, pp. 291-298, (2004).

[13] M. Wang, L. Gao and Y. Zheng, “An examination of the fundamental mechanics of cutting force coefficients”, Int. J. Mach. Tools Manuf., Vol. 78, pp. 1-7, (2014).

[14] M. Wan, M. S. Lu, W. H. Zhang and Y. Yang, “A new ternary-mechanism model for the prediction of CFs in flat end milling”, Int. J. Mach. Tools Manuf., Vol. 57, pp. 34 – 45, (2012).

[15] J. W. Dang, W. H. Zhang, Y. Yang and M. Wan, “Cutting force modeling for flat end milling including bottom edge cutting effect”, Int. J. Mach. Tools Manuf., Vol. 50, No. 11, pp. 986-997, (2010).

[16] M. Wan, W. H. Zhang, J. W. Dang and Y. Yang, “A novel cutting force modeling method for cylindrical end mill”, Appl. Math. Modell., Vol. 34, No. 3, pp. 823-836, (2010).

[17] A. Bhattacharyya, J. K. Schueller, B. P. Mann, J. C. Ziegert, T. L. Schmitz, F. J. Taylor and N. G. Fitz-Coy, “A closed form mechanistic cutting force model for helical peripheral milling of ductile metallic alloys”, Int. J. Mach. Tools Manuf., Vol. 50, No. 6, pp. 538-551, (2010).

[18] Y. C. Kao, N. T. Nguyen, M. S. Chen and S. C. Huang, “A combination method of the theory and experiment in determination of cutting force coefficients in ball-end mill processes”, J. Comput. Des. Eng., Vol. 2, No. 4, pp. 233-247, (2015).

[19] J. Gradišek, M. Kalveram and K. Weinert, “Mechanistic identification of specific force coefficients for a general end mill”, Int. J. Mach. Tools Manuf., Vol. 44, No. 4, pp. 401-414, (2004).

[20] I. G. Euan, E, Ozturk and N. D. Sims. (2013). Modeling Static and Dynamic CFs and Vibrations for Inserted Ceramic Milling Tools. Procedia CIRP, 8, 564–569, (2013).

[21] Y. C. Kao, N. T. Nguyen, M. S. Chen and S. T. Su, “A prediction method of cutting force coefficients with helix angle of flat-end cutter and its application in a virtual three-axis milling simulation system”, Int. J. Adv. Manuf. Technol., Vol. 77, No. 9-12, pp. 1793-1809, (2015).

[22] Q. Cao, J. Zhao, Y. Li and L. Zhu, “The effects of cutter eccentricity on the cutting force in the ball-end finish milling”, Int. J. Adv. Manuf. Technol., Vol. 69, No. 9-12, pp. 2843-2849, (2013).

[23] C. H. Lee, M. Y. Yang, C. W. Oh, T. W. Gim and J. Y. Ha, “An integrated prediction model including the cutting process for virtual product development of machine tools”, Int. J. Mach. Tools Manuf., Vol. 90, pp. 29–43, (2014).

[24] A. Agarwal and K. A. Desai, “Importance of bottom and flank edges in force models for flat-end milling operation”, Int. J. Adv. Manuf. Technol., Vol. 107, No. 3, pp.1437-1449, (2020).

[25] N. T. Nguyen, Modeling of Machining Dynamics: CFs and Machining Characteristics in Three-Axis Milling Processes. Science and technics publishing House, Hanoi, Vietnam, (2020).