An Approach to Theoretical Modeling and Simulation of Face Milling Forces |
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| Institution: | 1. Karlsruhe Institute of Technology (KIT), wbk Institute of Production Science, Kaiserstr. 12, 76131 Karlsruhe, Germany;2. Faculty of Mechanical Engineering, Karlsruhe Institute of Technology (KIT), Kaiserstr. 12, 76131 Karlsruhe, Germany;1. Department of Gastroenterology, Baoji Central hospital, Baoji 721008, China;2. Department of Oncology, the First Affiliated Hospital of Xi''an Medical University, Xi’an 710003, China;3. Department of Pathology, the First Affiliated Hospital of Xi’an Jiaotong University, Xi’an 710061, China;1. ITER, S‘O’A University, Bhubaneswar, 751030, India;2. Mechanical Engineering Department, ITER, S‘O’A University, Bhubaneswar, 751030, India;1. School of Materials Science and Engineering, Hefei University of Technology, Hefei 230009, China;2. Anhui Province Key Laboratory of Microsystem, Hefei 230088, China;3. Electric Power Research Institute, State Grid Anhui Electric Power Co., Ltd., Hefei 230601, China;4. Hefei Shengda Electronic Technology Industry Co. Ltd., Hefei 230088, China;5. Engineering Research Center of High Performance Copper Alloy Materials and Processing, Ministry of Education, Hefei 230009, China |
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| Abstract: | A new approach to theoretical modeling and simulation of face milling forces is presented. The present approach is based on a predictive machining theory in which machining characteristic factors in continuous cutting with a single-point cutting tool can be predicted from the workpiece material properties, tool geometry, and cutting conditions. The action of a milling cutter is considered as the simultaneous work of a number of single-point cutting tools, and the milling forces are predicted from input data of workpiece material properties, cutter parameters and tooth geometry, cutting condition, cutter and workpiece vibration structure parameters, and types of milling. A predictive force model for face milling is developed using this approach. In the model, the workpiece material properties are considered as functions of strain, strain rate, and temperature. The ratio of cutter tooth engagement over milling is taken into account for the determination of temperature in the cutting region. Cutter runout is included in the modeling for the chip load. The relative displacement between the cutter and workpiece due to the cutter and workpiece vibration is also included in the modeling to consider the effect on the undeformed chip thickness. A milling force simulation system has been developed using the model, and face milling experimental tests have been conducted to verify the simulation system. It is shown that the simulation results agree well with experimental results. |
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