Identification of Polynomial Cutting Coefficients for a Dual-Mechanism Ball-end Milling Force Model

Author(s): Zhixin Feng*, Meng Liu, Guohe Li.

Journal Name: Recent Patents on Engineering

Volume 13 , Issue 3 , 2019

Become EABM
Become Reviewer

Graphical Abstract:


Abstract:

Background: Calibration of cutting coefficients is the key content in modeling a mechanistic cutting force model. Generally, in modeling cutting force for ball end milling, the tangent, radial and binormal cutting force coefficients are each considered as a polynomial, respectively. This fact is due to the dependency between the cutting force coefficients and the cutting edge inclination angle which is variable in ball-end mills.

Objective: This paper presents an approach to determine the polynomial cutting force coefficients.

Methods: In this approach, the cutting force coefficients are expressed as explicit linear equations about the average slotting forces. After analysis of the least square regression method which is utilized in the cutting coefficients evaluation, the principle of cutting parameters choice in calibration experiment and the relationship between the order of polynomial and the number of experiments are presented. Besides, a lot of patents on identification of polynomial cutting coefficients for milling force model were studied.

Results: Finally, a series of semi-slotting verification cutting tests were arranged, the measured force agrees well with the predicted force, which demonstrates the effectiveness of this approach.

Conclusion: Based on the calibration method proposed in this paper, the cutting coefficients can be determined through (m+2) slotting experiments for m-degree shearing coefficients polynomial theoretically.

Keywords: Ball-end mill, cutting force, cutting coefficients, coefficients calibration, polynomial, cutting edge.

[1]
E.J.A. Armaregoa, and N.P. Deshpandea, "“Computerized End-Milling Force Predictions with Cutting Models Allowing for Eccentricity and Cutter Deflections”, CIRP Ann.-", Manuf. Tech, vol. 40, pp. 25-29, 1991.
[2]
R. Yan, F. Y. Peng, F. Qiu, Y. Wang, S. Lin, and B. Li, "A modeling method for cutting force of orthogonal car and milling shaft parts with flat bottom spiral end milling cutter", CN Patent 10,364, 6141A,, 2014.
[3]
W.J. Endres, R.E. DeVor, and S.G. Kapoor, "A Dual-Mechanism Approach to the Prediction of Machining Forces, Part 2: Calibration and Validation", J. Eng. Ind., vol. 117, pp. 534-541, 1995.
[4]
E. Budak, Y. Altintas, and E.J.A. Armarego, "Prediction of Milling Force Coefficients From Orthogonal Cutting Data", ASME J. Manuf. Sci. Eng, vol. 118, pp. 216-224, 1996.
[5]
P. Lee, and Y. Altintas, "Prediction of ball-end milling forces from orthogonal cutting data", Int. J. Mach. Tools Manuf., vol. 36, pp. 1059-1072, 1996.
[6]
G. Yucesan, and Y. Altintas, "Prediction of Ball End Milling Forces", J. Eng. Ind., vol. 118, pp. 95-103, 1996.
[7]
Z. H. An, X. L. Fu, Y. A. Pan, and Y. Wang, "A modeling method for multi cycle milling using intermittent turning simulation", CN Patent 10, 469, 9919A, 2015.
[8]
J.J.J. Wang, and C.M. Zheng, "Identification of shearing and ploughing cutting constants from average forces in ball-end milling", Int. J. Mach. Tools Manuf., vol. 42, pp. 695-705, 2002.
[9]
Q. Liu, W. W. Qiu, S. M. Yuan, and C. J. Li, "A modeling method for cutting force of end edge of orthogonal vehicle milling machining based on boundary condition judgment", CN Patent 10,479,4337A, 2015.
[10]
H.Y. Feng, and C.H. Menq, "The prediction of cutting forces in the ball-end milling process--I. Model formulation and model building procedure", Int. J. Mach. Tools Manuf., vol. 34, pp. 697-710, 1994.
[11]
B.M. Imani, M.H. Sadeghi, and M.A. Elbestawi, "An improved process simulation system for ball-end milling of sculptured surfaces", Int. J. Mach. Tools Manuf., vol. 38, pp. 1089-1107, 1998.
[12]
A. Azeem, H.Y. Feng, and L.H. Wang, "Simplified and efficient calibration of a mechanistic cutting force model for ball-end milling", Int. J. Mach. Tools Manuf., vol. 44, pp. 291-298, 2004.
[13]
J. Gradisek, M. Kalveram, and K. Weinert, "Mechanistic identification of specific force coefficients for a general end mill", Int. J. Mach. Tools Manuf., vol. 44, pp. 401-414, 2004.
[14]
F. Y. Peng, L. Zhou, C. C. Yang, P. F. Yao, C. Zhan, and M. Liu, "A modeling method for cutting force of free-form surface micro milling", CN Patent 10,506,9257A,, 2015.
[15]
A. Lamikiz, L.N. Lopez de Lacalle, J.A. Sanchez, and U. Bravo, "Calculation of the specific cutting coefficients and geometrical aspects in sculptured surface machining", Mach. Sci. Technol., vol. 9, pp. 411-436, 2005.
[16]
M. Wan, W.H. Zhang, J.W. Dang, and Y. Yang, "New procedures for calibration of instantaneous cutting force coefficients and cutter runout parameters in peripheral milling", Int. J. Mach. Tools Manuf., vol. 49, pp. 1144-1151, 2009.
[17]
O. Gonzalo, J. Beristain, H. Jauregi, and C. Sanz, "A method for the identification of the specific force coefficients for mechanistic milling simulation", Int. J. Mach. Tools Manuf., vol. 50, pp. 765-774, 2010.
[18]
Z.Q. Yao, X.G. Liang, L. Luo, and J. Hua, "A chatter free calibration method for determining cutter runout and cutting force coefficients in ball-end milling", J. Mate. Pro. Tech., vol. 213, pp. 1575-1587, 2013.
[19]
C. T. Tian, H. L. Lv, and M. Zhang, "Prediction method of milling instantaneous cutting force based on maximum cutting force", CN Patent 10,668,2281A, 2017.
[20]
S.E. Layegh and I. Lazoglu,, "A New Identification Method of Specific Cutting Coefficients for Ball End Milling", Procedia CIRP, vol. 14, pp. 182-187, 2014.
[21]
K.M. Mao, M. Zhu, W.W. Xiao, and B. Li, "A method of using turning process excitation to determine dynamic cutting coefficients", Int. J. Mach. Tools Manuf., vol. 87, pp. 49-60, 2014.
[22]
M.H. Wang, L. Gao, and Y.H. Zheng, "An examination of the fundamental mechanics of cutting force coefficients", Int. J. Mach. Tools Manuf., vol. 78, pp. 1-7, 2014.
[23]
Y.C. Kao, N.T. Nguyen, M.S. Chen, and S.C. Huang, "A combination method of the theory and experiment in determination of cutting force coefficients in ball-end mill processes", J. Compu. Des. Eng., vol. 2, pp. 233-247, 2015.
[24]
P. Kolar, P. Fojtu, and T. Schmitz, "On Cutting Force Coefficient Mldel with Respect to Tool Geometry and Tool Wear", Procedia Manuf., vol. 1, pp. 708-720, 2015.
[25]
S. Wojciechowski, "The estimation of cutting forces and specific force coefficients during finishing ball end milling of inclined surfaces", Int. J. Mach. Tools Manuf., vol. 89, pp. 110-123, 2015.
[26]
Q. Cao, J. Zhao, S. Han, and X. Chen, "Force coefficients identification considering inclination angle for ball-end finish milling", Precis. Eng., vol. 36, pp. 252-260, 2012.
[27]
A. Lamikiz, L.N. Lopez de Lacalle, J.A. Sanchez, and U. Bravo, "Calculation of the specific cutting coefficients and geometrical aspects in sculptured surface machining", Mach. Sci. Technol., vol. 9, pp. 411-436, 2005.
[28]
Z.C. Wei, M.J. Wang, J.N. Zhu, and L.Y. Gu, "Cutting force prediction in ball end milling of sculptured surface with Z-level contouring tool path", Int. J. Mach. Tools Manuf., vol. 51, pp. 428-432, 2011.
[29]
Z.C. Wei, M.J. Wang, Y.J. Cai, and L. Wang, "Milling Force Prediction for Ball-end Milling of 3D Curved Surfaces", Chin. J. Mech. Eng., vol. 49, pp. 178-184, 2013.


Rights & PermissionsPrintExport Cite as

Article Details

VOLUME: 13
ISSUE: 3
Year: 2019
Page: [232 - 240]
Pages: 9
DOI: 10.2174/1872212112666180629142036
Price: $58

Article Metrics

PDF: 20
HTML: 2