Predicting the cutting forces required for five-axis flank milling is a challenging task due to the difficulties involved in determining the Undeformed Chip Thickness(UCT) and CutterWorkpiece Engagement(CWE). To solve...Predicting the cutting forces required for five-axis flank milling is a challenging task due to the difficulties involved in determining the Undeformed Chip Thickness(UCT) and CutterWorkpiece Engagement(CWE). To solve these problems, this paper presents a new mechanistic cutting force model based on the geometrical analysis of a flank milling process. In the model,the part feature and corresponding cutting location data are taken as input information. The UCT considering cutter runout is calculated according to the instantaneous feed rate of the element cutting edges. A solid-discrete-based method is used to precisely and efficiently identify the CWE between the end mill and the surface being machined. Then, after calibrating the specific force coef-ficients, the mechanistic milling force can be obtained. During the validation process, two practical operations, three-axis flank milling of a vertical surface and five-axis flank milling of a nondevelopable ruled surface, are conducted. Comparisons between predicted and measured cutting forces demonstrate the reliability of the proposed cutting force model.展开更多
It is extremely important to select appropriate feedrates for the stable machining of parts with ruled surface in modern aviation industrial applications.However,the current studies take too much time to achieve this ...It is extremely important to select appropriate feedrates for the stable machining of parts with ruled surface in modern aviation industrial applications.However,the current studies take too much time to achieve this goal.Therefore,this paper presents an efficient feedrate optimization method for constant peak cutting force in five-axis flank milling process.The solution method of the instantaneous undeformed chip thickness(IUCT)is proposed using least squares theory with the cutter entry angle and feedrate as variables.Based on this method,an explicit analytical expression of the peak cutting force for each cutting point is established.Furthermore,a feedrate scheduling method is developed to quickly solve the appropriate feedrate under constant peak cutting force.To verify the proposed IUCT model,the fitting IUCT is compared with the accuracy data at different feedrates.Additionally,some experiments of five-axis flank milling are conducted to demonstrate the effectiveness of the peak force model and the feedrate scheduling method.And the surface roughness before and after feedrate scheduling is detected.The results show that the proposed feedrate scheduling method can quickly adjust the feedrate and ensure constant peak force during machining.At the same time,the surface quality is kept at a high level.展开更多
基金co-supported by the Major National S&T Program(No.2014ZX04014-031)the National Natural Science Foundation of China(No.51225503)
文摘Predicting the cutting forces required for five-axis flank milling is a challenging task due to the difficulties involved in determining the Undeformed Chip Thickness(UCT) and CutterWorkpiece Engagement(CWE). To solve these problems, this paper presents a new mechanistic cutting force model based on the geometrical analysis of a flank milling process. In the model,the part feature and corresponding cutting location data are taken as input information. The UCT considering cutter runout is calculated according to the instantaneous feed rate of the element cutting edges. A solid-discrete-based method is used to precisely and efficiently identify the CWE between the end mill and the surface being machined. Then, after calibrating the specific force coef-ficients, the mechanistic milling force can be obtained. During the validation process, two practical operations, three-axis flank milling of a vertical surface and five-axis flank milling of a nondevelopable ruled surface, are conducted. Comparisons between predicted and measured cutting forces demonstrate the reliability of the proposed cutting force model.
基金co-supported by the Major National S&T Program(2017ZX04002001)the Major National S&T Program(2016ZX04004004)。
文摘It is extremely important to select appropriate feedrates for the stable machining of parts with ruled surface in modern aviation industrial applications.However,the current studies take too much time to achieve this goal.Therefore,this paper presents an efficient feedrate optimization method for constant peak cutting force in five-axis flank milling process.The solution method of the instantaneous undeformed chip thickness(IUCT)is proposed using least squares theory with the cutter entry angle and feedrate as variables.Based on this method,an explicit analytical expression of the peak cutting force for each cutting point is established.Furthermore,a feedrate scheduling method is developed to quickly solve the appropriate feedrate under constant peak cutting force.To verify the proposed IUCT model,the fitting IUCT is compared with the accuracy data at different feedrates.Additionally,some experiments of five-axis flank milling are conducted to demonstrate the effectiveness of the peak force model and the feedrate scheduling method.And the surface roughness before and after feedrate scheduling is detected.The results show that the proposed feedrate scheduling method can quickly adjust the feedrate and ensure constant peak force during machining.At the same time,the surface quality is kept at a high level.
