A new mechanistic cutting force model for flat end milling using the instantaneous cutting force coefficients is proposed. An in-depth analysis shows that the total cutting forces can be separated into two terms: a no...A new mechanistic cutting force model for flat end milling using the instantaneous cutting force coefficients is proposed. An in-depth analysis shows that the total cutting forces can be separated into two terms: a nominal component independent of the runout and a perturbation component induced by the runout. The instantaneous value of the nominal component is used to calibrate the cutting force coefficients. With the help of the perturbation component and the cutting force coefficients obtained above, the cutter runout is identified. Based on simulation and experimental results, the validity of the identification approach is demonstrated. The advantage of the proposed method lies in that the calibration performed with data of one cutting test under a specific regime can be applied for a great range of cutting conditions.展开更多
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
扇形喷嘴越来越广泛地应用于清洗作业,但不同切割结构的扇形喷嘴具有不同的性能。采用VOF(volume of fluid)两相流模型,运用CFD(computational fluid dynamics)软件对扇形喷嘴及其外流场进行了数值模拟,研究了当扇形喷嘴出口截面面积一...扇形喷嘴越来越广泛地应用于清洗作业,但不同切割结构的扇形喷嘴具有不同的性能。采用VOF(volume of fluid)两相流模型,运用CFD(computational fluid dynamics)软件对扇形喷嘴及其外流场进行了数值模拟,研究了当扇形喷嘴出口截面面积一定时,不同的切槽形状和加工方式对清洗效果的影响。研究结果表明:相同的加工方式,V形槽的喷射角略高于U形槽,圆弧形槽的喷射角最小。但在有效作用域上和有效打击力方面,圆弧形槽的最大,U形槽略大于V形槽;水平铣槽加工方式的射流角度和质量流量均大于圆弧铣槽的;圆弧铣槽加工方式相比水平铣槽能提高V形槽和U形槽的清洗能力,但却削弱了圆弧形槽的清洗能力。展开更多
基金National Natural Science Foundation of China (50435020) Natural Science Foundation of Shaanxi Province(2004E217)+1 种基金the Doctorate Creation Foundation of Northwestern Polytechnical Uni-versity (CX200411)Youth for NPU Teachers Scientific and Technologi-cal Innovation Foundation
文摘A new mechanistic cutting force model for flat end milling using the instantaneous cutting force coefficients is proposed. An in-depth analysis shows that the total cutting forces can be separated into two terms: a nominal component independent of the runout and a perturbation component induced by the runout. The instantaneous value of the nominal component is used to calibrate the cutting force coefficients. With the help of the perturbation component and the cutting force coefficients obtained above, the cutter runout is identified. Based on simulation and experimental results, the validity of the identification approach is demonstrated. The advantage of the proposed method lies in that the calibration performed with data of one cutting test under a specific regime can be applied for a great range of cutting conditions.
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.
文摘扇形喷嘴越来越广泛地应用于清洗作业,但不同切割结构的扇形喷嘴具有不同的性能。采用VOF(volume of fluid)两相流模型,运用CFD(computational fluid dynamics)软件对扇形喷嘴及其外流场进行了数值模拟,研究了当扇形喷嘴出口截面面积一定时,不同的切槽形状和加工方式对清洗效果的影响。研究结果表明:相同的加工方式,V形槽的喷射角略高于U形槽,圆弧形槽的喷射角最小。但在有效作用域上和有效打击力方面,圆弧形槽的最大,U形槽略大于V形槽;水平铣槽加工方式的射流角度和质量流量均大于圆弧铣槽的;圆弧铣槽加工方式相比水平铣槽能提高V形槽和U形槽的清洗能力,但却削弱了圆弧形槽的清洗能力。
