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
axis NC machining freeform surface with a flat end cutter can theoretically improve material removal rate and surface finish, but it is very difficult to generate a gouge free cutter location. A new method of gener...axis NC machining freeform surface with a flat end cutter can theoretically improve material removal rate and surface finish, but it is very difficult to generate a gouge free cutter location. A new method of generating optimal cutter path is proposed to define the effective radius of a flat end cutter and determine the optimal step forward distance and step over distance. Thereby improving the NC machining efficiency and quality of freeform surfaces.展开更多
Multiscale simulations of the tilted flat-ended nanoindentation with different tilted angles （from 5° ～ 30°） on the （-1 1 0） surface of nickel crystal were studied using the QC method. The model of the ...Multiscale simulations of the tilted flat-ended nanoindentation with different tilted angles （from 5° ～ 30°） on the （-1 1 0） surface of nickel crystal were studied using the QC method. The model of the indentation is a flat-end indenter inclined by an angle ε driven into a half- plane vertically. Load-displacement responses, initiM stages of the plasticity deformations and dislocation emissions for nickel film at different inclined angles were obtained and analyzed as well. An energy criterion was successfully proposed to analyze the critical load for the first dislocation emission beneath the edge of the indenter. Simulation results agree well with analytical ones. An elastic model based on the contact theory and the Peierls-Nabarro dislocation model were combined to analyze when and where the dislocation will be emitted beneath the lower surface of an inclined indenter. Results indicate that the key parameter is the ratio of the contact half- width to the position of the slip plane. This parameter shows the range in which a dislocation will probably be emitted. This mechanism explains the simulation results well. This work is of value for understanding the mechanism of dislocation emissions of FCC crystals under tilted flat- ended nanoindentation while providing approaches to predicting when the first dislocation will be emitted and where subsequent dislocations will probably be emitted.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.
文摘axis NC machining freeform surface with a flat end cutter can theoretically improve material removal rate and surface finish, but it is very difficult to generate a gouge free cutter location. A new method of generating optimal cutter path is proposed to define the effective radius of a flat end cutter and determine the optimal step forward distance and step over distance. Thereby improving the NC machining efficiency and quality of freeform surfaces.
基金supported by the Science and Technology Innovation Talents Special Fund of Harbin(No.2012RFQXG001)the National Natural Science Foundation of China(No.11102053)the China Scholarship Council(CSC)
文摘Multiscale simulations of the tilted flat-ended nanoindentation with different tilted angles （from 5° ～ 30°） on the （-1 1 0） surface of nickel crystal were studied using the QC method. The model of the indentation is a flat-end indenter inclined by an angle ε driven into a half- plane vertically. Load-displacement responses, initiM stages of the plasticity deformations and dislocation emissions for nickel film at different inclined angles were obtained and analyzed as well. An energy criterion was successfully proposed to analyze the critical load for the first dislocation emission beneath the edge of the indenter. Simulation results agree well with analytical ones. An elastic model based on the contact theory and the Peierls-Nabarro dislocation model were combined to analyze when and where the dislocation will be emitted beneath the lower surface of an inclined indenter. Results indicate that the key parameter is the ratio of the contact half- width to the position of the slip plane. This parameter shows the range in which a dislocation will probably be emitted. This mechanism explains the simulation results well. This work is of value for understanding the mechanism of dislocation emissions of FCC crystals under tilted flat- ended nanoindentation while providing approaches to predicting when the first dislocation will be emitted and where subsequent dislocations will probably be emitted.
