Ball-end mill is widely used in workpiece processi ng with free-form surfaces. Such models that can predict processing character istics precisely are very necessary to the aim of cost reducing, quality improvi ng and ...Ball-end mill is widely used in workpiece processi ng with free-form surfaces. Such models that can predict processing character istics precisely are very necessary to the aim of cost reducing, quality improvi ng and productivity progressing, the cutting force prediction is the most import ant among these models. To explore the physical essence of metal cutting, model researchers commonly simplify the geometric conditions in cutting process, and a ssume that the geometric parameters that are needed to solve the physical models have already been predefined, so it results in the separation between model res earch and practical application. In this paper, for the representative cutting f orce models of ball end milling, a new extraction method of geometric parameters is suggested, which makes it possible for physical model to actually serve for the practical manufacturing, and take in the inspection of real production.展开更多
Milling Process Simulation is one of the important re search areas in manufacturing science. For the purpose of improving the prec ision of simulation and extending its usability, numerical algorithm is more and more ...Milling Process Simulation is one of the important re search areas in manufacturing science. For the purpose of improving the prec ision of simulation and extending its usability, numerical algorithm is more and more used in the milling modeling areas. But simulative efficiency is decreasin g with increase of its complexity. As a result, application of the method is lim ited. Aimed at above question, high-efficient algorithm for milling process sim ulation is studied. It is important for milling process simulation’s applicatio n. Parallel computing is widely used to solve the large-scale computation question s. Its advantages include system flexibility, robust, high-efficient computing capability and high ratio of performance to price. With the development of compu ter network, utilizing the computing resource in the Internet, a virtual computi ng environment with powerful computing capability can be consisted by microc omputers, and the difficulty of building hardware environment which is used to s upport parallel computing is reduced. How to use network technology and parallel algorithm to improve simulative effic iency for milling forces simulation is investigated in the paper. In order to pr edict milling forces, a simplified local milling forces model is used in the pap er. End milling cutter is assumed to be divided by r number of differential elem ents along the axial direction of the cutter. For a given time, the total cuttin g forces can be obtained by summarizing the resultant cutting force produced by each differential cutter disc. Divide the whole simulative time into some segmen ts, send these program’s segments to microcomputers in the Internet and obtain the result of the program’s segments, all of the result of program’s segments a re composed the final result. For implementing the algorithm, a distributed Parallel computing framework is de signed in the paper. In the framework, web server plays a role of controller. Us ing Java RMI(remote method interface), the computing processes in computing serv er are called by web server. There are lots of control processes in web server a nd control the computing servers. The codes of simulative algorithm can be dynam ic sent to the computing servers, and milling forces at the different time are c omputed through utilizing the local computer’s resource. The results that are ca lculated by every computing servers are sent to the web server, and composed the final result. The framework can be used by different simulative algorithm. Comp ared with the algorithm running single machine, the efficiency of provided algor ithm is higher than that of single machine.展开更多
Discrete Element Method (DEM) is a powerful tool for simulating different types of mills. It also used for computing different types of particles such as rocks, grains, and molecules.</span></span><span...Discrete Element Method (DEM) is a powerful tool for simulating different types of mills. It also used for computing different types of particles such as rocks, grains, and molecules.</span></span><span style="white-space:normal;"><span style="font-family:""> </span></span><span style="white-space:normal;"><span style="font-family:"">DEM has been widely used in the field of rock mechanics. In the present work,</span></span><span style="white-space:normal;"><span style="font-family:""> </span></span><span style="white-space:normal;"><span style="font-family:"">DEM approach is applied to model the milling media (powder particles and balls) inside a planetary ball mill and to estimate the distribution of particles of a dry powder during milling. In fact, the efficiency of the DEM strongly depends on the input parameters. The DEM simulation results indicated that</span></span><span style="white-space:normal;"><span style="font-family:""> </span></span><span style="white-space:normal;"><span style="font-family:"">DEM is a promising tool for the simulation of the dynamic particles motion and interactions within planetary ball mill. These results could be utilized to further develop the synthesis performance, anticipate the reaction, and reduce the wear in the dry milling reactions.展开更多
In accordance with the relative movement between end-milling cutter and workpiece surface, a theoretical generation model for milled surface was established with the movement error of principal axle considered. Then t...In accordance with the relative movement between end-milling cutter and workpiece surface, a theoretical generation model for milled surface was established with the movement error of principal axle considered. Then the milled surfaces under various cutting condition were simulated, the results of which showed that end milled surfaces were of "vaulted profile", heights of surface irregularty at various points to be different with maximum value in the middle and smaller at both sides, the difference were determined by diameter of milling cutter, feeding speed, ratio between the diameter of milling cutter and teeth point curve radius and width of workpiece. The study results can be applied to quality prediction of milled surfaces for precision and/or super precision milling operation.展开更多
Machining of carbon/carbon (C/C) composite materials is difficult to carry out due to its high specific stiffness, brittleness, anisotropic, non-homogeneous and low thermal conductivity, which can result in tear, bu...Machining of carbon/carbon (C/C) composite materials is difficult to carry out due to its high specific stiffness, brittleness, anisotropic, non-homogeneous and low thermal conductivity, which can result in tear, burr, poor surface quality and rapid wear of cutters. Accurate and fast pre- diction of cutting forces is important for milling C/C composite materials with high quality. This paper presents an alternative cutting force model involving the influences of the directions of fiber. Based on the calculated and experimental results, the cutting forces" coefficients of 2.5D CC com- posites are evaluated using multiple linear regression method. Verification experiment has been car- ried out through a group of orthogonal tests. Results indicate that the proposed nmdel is reliable and can be used to predict the cutting forces in ball-end milling of 2.5D C/C composites.展开更多
Abstract Predictive models for machining operations have been significantly improved through numerous methods in recent decades. This study proposed a 3D finite element modeling (3D FEM) approach for the micro end-m...Abstract Predictive models for machining operations have been significantly improved through numerous methods in recent decades. This study proposed a 3D finite element modeling (3D FEM) approach for the micro end-milling orAl6061-T6. Finite element (FE) simulations were performed under different cutting conditions to obtain realistic numerical predictions of chip flow, burr formation, and cutting forces. FE modeling displayed notable advantages, such as capability to easily handle any type of tool geometry and any side effect on chip formation, including thermal aspect and material property changes. The proposed 3D FE model considers the effects ofmiU helix angle and cutting edge radius on the chip. The prediction capability of the FE model was validated by comparing numerical model and experimental test results. Burr dimension trends were correlated with force profile shapes. However, the FE predictions overestimated the real force magnitude. This overestimation indicates that the model requires further development.展开更多
文摘Ball-end mill is widely used in workpiece processi ng with free-form surfaces. Such models that can predict processing character istics precisely are very necessary to the aim of cost reducing, quality improvi ng and productivity progressing, the cutting force prediction is the most import ant among these models. To explore the physical essence of metal cutting, model researchers commonly simplify the geometric conditions in cutting process, and a ssume that the geometric parameters that are needed to solve the physical models have already been predefined, so it results in the separation between model res earch and practical application. In this paper, for the representative cutting f orce models of ball end milling, a new extraction method of geometric parameters is suggested, which makes it possible for physical model to actually serve for the practical manufacturing, and take in the inspection of real production.
文摘Milling Process Simulation is one of the important re search areas in manufacturing science. For the purpose of improving the prec ision of simulation and extending its usability, numerical algorithm is more and more used in the milling modeling areas. But simulative efficiency is decreasin g with increase of its complexity. As a result, application of the method is lim ited. Aimed at above question, high-efficient algorithm for milling process sim ulation is studied. It is important for milling process simulation’s applicatio n. Parallel computing is widely used to solve the large-scale computation question s. Its advantages include system flexibility, robust, high-efficient computing capability and high ratio of performance to price. With the development of compu ter network, utilizing the computing resource in the Internet, a virtual computi ng environment with powerful computing capability can be consisted by microc omputers, and the difficulty of building hardware environment which is used to s upport parallel computing is reduced. How to use network technology and parallel algorithm to improve simulative effic iency for milling forces simulation is investigated in the paper. In order to pr edict milling forces, a simplified local milling forces model is used in the pap er. End milling cutter is assumed to be divided by r number of differential elem ents along the axial direction of the cutter. For a given time, the total cuttin g forces can be obtained by summarizing the resultant cutting force produced by each differential cutter disc. Divide the whole simulative time into some segmen ts, send these program’s segments to microcomputers in the Internet and obtain the result of the program’s segments, all of the result of program’s segments a re composed the final result. For implementing the algorithm, a distributed Parallel computing framework is de signed in the paper. In the framework, web server plays a role of controller. Us ing Java RMI(remote method interface), the computing processes in computing serv er are called by web server. There are lots of control processes in web server a nd control the computing servers. The codes of simulative algorithm can be dynam ic sent to the computing servers, and milling forces at the different time are c omputed through utilizing the local computer’s resource. The results that are ca lculated by every computing servers are sent to the web server, and composed the final result. The framework can be used by different simulative algorithm. Comp ared with the algorithm running single machine, the efficiency of provided algor ithm is higher than that of single machine.
文摘Discrete Element Method (DEM) is a powerful tool for simulating different types of mills. It also used for computing different types of particles such as rocks, grains, and molecules.</span></span><span style="white-space:normal;"><span style="font-family:""> </span></span><span style="white-space:normal;"><span style="font-family:"">DEM has been widely used in the field of rock mechanics. In the present work,</span></span><span style="white-space:normal;"><span style="font-family:""> </span></span><span style="white-space:normal;"><span style="font-family:"">DEM approach is applied to model the milling media (powder particles and balls) inside a planetary ball mill and to estimate the distribution of particles of a dry powder during milling. In fact, the efficiency of the DEM strongly depends on the input parameters. The DEM simulation results indicated that</span></span><span style="white-space:normal;"><span style="font-family:""> </span></span><span style="white-space:normal;"><span style="font-family:"">DEM is a promising tool for the simulation of the dynamic particles motion and interactions within planetary ball mill. These results could be utilized to further develop the synthesis performance, anticipate the reaction, and reduce the wear in the dry milling reactions.
文摘In accordance with the relative movement between end-milling cutter and workpiece surface, a theoretical generation model for milled surface was established with the movement error of principal axle considered. Then the milled surfaces under various cutting condition were simulated, the results of which showed that end milled surfaces were of "vaulted profile", heights of surface irregularty at various points to be different with maximum value in the middle and smaller at both sides, the difference were determined by diameter of milling cutter, feeding speed, ratio between the diameter of milling cutter and teeth point curve radius and width of workpiece. The study results can be applied to quality prediction of milled surfaces for precision and/or super precision milling operation.
基金supported by the National Natural Science Foundation of China(No.51105312)the Fundamental Research Funds for the Central University of China(No.3102015JCS05005)
文摘Machining of carbon/carbon (C/C) composite materials is difficult to carry out due to its high specific stiffness, brittleness, anisotropic, non-homogeneous and low thermal conductivity, which can result in tear, burr, poor surface quality and rapid wear of cutters. Accurate and fast pre- diction of cutting forces is important for milling C/C composite materials with high quality. This paper presents an alternative cutting force model involving the influences of the directions of fiber. Based on the calculated and experimental results, the cutting forces" coefficients of 2.5D CC com- posites are evaluated using multiple linear regression method. Verification experiment has been car- ried out through a group of orthogonal tests. Results indicate that the proposed nmdel is reliable and can be used to predict the cutting forces in ball-end milling of 2.5D C/C composites.
文摘Abstract Predictive models for machining operations have been significantly improved through numerous methods in recent decades. This study proposed a 3D finite element modeling (3D FEM) approach for the micro end-milling orAl6061-T6. Finite element (FE) simulations were performed under different cutting conditions to obtain realistic numerical predictions of chip flow, burr formation, and cutting forces. FE modeling displayed notable advantages, such as capability to easily handle any type of tool geometry and any side effect on chip formation, including thermal aspect and material property changes. The proposed 3D FE model considers the effects ofmiU helix angle and cutting edge radius on the chip. The prediction capability of the FE model was validated by comparing numerical model and experimental test results. Burr dimension trends were correlated with force profile shapes. However, the FE predictions overestimated the real force magnitude. This overestimation indicates that the model requires further development.