The cutting force prediction is essential to optimize the process parameters of machining such as feed rate optimization, etc. Due to the significant influences of the runout effect on cutting force variation in milli...The cutting force prediction is essential to optimize the process parameters of machining such as feed rate optimization, etc. Due to the significant influences of the runout effect on cutting force variation in milling process, it is necessary to incorporate the cutter runout parameters into the prediction model of cutting forces. However, the determination of cutter runout parameters is still a challenge task until now. In this paper, cutting process geometry models, such as uncut chip thickness and pitch angle, are established based on the true trajectory of the cutting edge considering the cutter runout effect. A new algorithm is then presented to compute the cutter runout parameters for flat-end mill utilizing the sampled data of cutting forces and derived process geometry parameters. Further, three-axis and five-axis milling experiments were conducted on a machining centre, and resulting cutting forces were sampled by a three-component dynamometer. After computing the corresponding cutter runout parameters, cutter forces are simulated embracing the cutter runout parameters obtained from the proposed algorithm. The predicted cutting forces show good agreements with the sampled data both in magnitude and shape, which validates the feasibility and effectivity of the proposed new algorithm of determining cutter runout parameters and the new way to accurately predict cutting forces. The proposed method for computing the cutter runout parameters provides the significant references for the cutting force prediction in the cutting process.展开更多
Five-axis ball-end milling is commonly used to machine the complex surfaces. Local tool interference phenomenon which often occurs in five-axis milling should be urgently solved. In this paper, a simplified method to ...Five-axis ball-end milling is commonly used to machine the complex surfaces. Local tool interference phenomenon which often occurs in five-axis milling should be urgently solved. In this paper, a simplified method to detect the occurrence of local tool interference and modify tool position is proposed. First, the detection matrix is established to detect local tool interference at all the cutter location points on tool path simultaneously in five-axis ball-end milling of complex surfaces. The algorithm of detection matrix based on point arithmetic is simple. Secondly, the new coordinates of the modified interfering-free points are obtained precisely by using the genetic algorithm. The feasibility of the method is validated by simulation in Matlab. This research is benefit to simplify the calculation of local tool interference detection and tool position modification.展开更多
Geometry of end mill cutters plays a vital role in the stability of the flexible parts milling.The present study considers helix angle and number of flutes.Multi-frequency solution is established to draw stability Lob...Geometry of end mill cutters plays a vital role in the stability of the flexible parts milling.The present study considers helix angle and number of flutes.Multi-frequency solution is established to draw stability Lobe diagram(SLD)for different helix angles and number of flutes.SLD for the two cases shows that the greater the value of helix angle,the more stable the milling process will be,and conversely increasing the number of flutes degrades the stability of flexible parts milling.A simple empirical methodology is adopted to employ the inclined plane workpiece geometry offering agradual increase of the axial depth of cut in the feed direction.Surface roughness is used as a measure of stability.Test results corroborate the model conclusions very well.展开更多
基金supported by National Natural Science Foundation of China (Grant No. 51075054)National Basic Research Program of China (973 Program, Grant No. 2005CB724100)Program for New Century Excellent Talents in University of China (Grant No. NCET-08-081)
文摘The cutting force prediction is essential to optimize the process parameters of machining such as feed rate optimization, etc. Due to the significant influences of the runout effect on cutting force variation in milling process, it is necessary to incorporate the cutter runout parameters into the prediction model of cutting forces. However, the determination of cutter runout parameters is still a challenge task until now. In this paper, cutting process geometry models, such as uncut chip thickness and pitch angle, are established based on the true trajectory of the cutting edge considering the cutter runout effect. A new algorithm is then presented to compute the cutter runout parameters for flat-end mill utilizing the sampled data of cutting forces and derived process geometry parameters. Further, three-axis and five-axis milling experiments were conducted on a machining centre, and resulting cutting forces were sampled by a three-component dynamometer. After computing the corresponding cutter runout parameters, cutter forces are simulated embracing the cutter runout parameters obtained from the proposed algorithm. The predicted cutting forces show good agreements with the sampled data both in magnitude and shape, which validates the feasibility and effectivity of the proposed new algorithm of determining cutter runout parameters and the new way to accurately predict cutting forces. The proposed method for computing the cutter runout parameters provides the significant references for the cutting force prediction in the cutting process.
基金Funded by the National Natural Science Foundation of China (No.51575321)the Major Science and Technology Innovation Project of Shandong Province (No.2018CXGC0804)Taishan Scholars Program of Shandong Province (No.ts201712002)
文摘Five-axis ball-end milling is commonly used to machine the complex surfaces. Local tool interference phenomenon which often occurs in five-axis milling should be urgently solved. In this paper, a simplified method to detect the occurrence of local tool interference and modify tool position is proposed. First, the detection matrix is established to detect local tool interference at all the cutter location points on tool path simultaneously in five-axis ball-end milling of complex surfaces. The algorithm of detection matrix based on point arithmetic is simple. Secondly, the new coordinates of the modified interfering-free points are obtained precisely by using the genetic algorithm. The feasibility of the method is validated by simulation in Matlab. This research is benefit to simplify the calculation of local tool interference detection and tool position modification.
文摘Geometry of end mill cutters plays a vital role in the stability of the flexible parts milling.The present study considers helix angle and number of flutes.Multi-frequency solution is established to draw stability Lobe diagram(SLD)for different helix angles and number of flutes.SLD for the two cases shows that the greater the value of helix angle,the more stable the milling process will be,and conversely increasing the number of flutes degrades the stability of flexible parts milling.A simple empirical methodology is adopted to employ the inclined plane workpiece geometry offering agradual increase of the axial depth of cut in the feed direction.Surface roughness is used as a measure of stability.Test results corroborate the model conclusions very well.
