Abstract
This paper presents a modeling method of cutting force and a combination approach of theory and experimental methods in the determination of cutting force coefficients in the face milling process using a parallelogram insert. By the theoretical method, the cutting forces were modeled by a mathematical function of cutting cutter geometry (Cutter diameter, the number of inserts, the insert nose radius, insert cutting edge helix angle, etc.), cutting conditions (depth of cut, feed per flute, spindle speed, etc.), and cutting force coefficients (shear force coefficients, edge force coefficients). By the theoretical method, the average cutting forces in three directions (feed – x, normal – y, and axial – z) were modeled as the linear functions of feed per flute. By the experimental method, the average cutting forces in these three directions were also regressed as the linear functions of feed per flute with quite large determination coefficients (R2 were larger than 92 %). Then, the relationship of average cutting forces and feed per flute was used to determine all six cutting force coefficient components. The validation experiments were performed to verify the linear function of average cutting forces, to determine the cutting force coefficients, and to verify the cutting force models in the face milling process using a cutter with one parallelogram insert. The cutting force models were successfully verified by comparison of the shape and the values of predicted cutting forces and measured cutting forces. These proposed methods and models can be applied to determine the cutting force coefficients and predict the cutting force in the face milling process using a parallelogram insert and can be extended with other cutting types or other insert types
Highlights
Nowadays, milling is very popularly employed in computer numerical control (CNC) machines for metal material cutting operations
This method was only applied in limited conditions, and the regression model changed with different conditions of experimental. This method was only applied separately for each pair of tool and workpiece, and the cutting force model changed when applying for different pairs of tool and workpiece. Several researchers applied this method in the investigation of cutting force in the face milling process of SKD61 Hard Steel [1], flat milling process of aerospace aluminum alloys [2], ball milling graded material [3], and so on
The average cutting force in feed, normal, and axial directions were calculated from the measured data of cutting forces
Summary
Nowadays, milling is very popularly employed in computer numerical control (CNC) machines for metal material cutting operations. The cutting force was modeled by the regression model through expe rimental data By using this method, the effect of the controllable factors such as cutting conditions, tool geometry, etc., on the cutting force was investigated. This method was only applied separately for each pair of tool and workpiece, and the cutting force model changed when applying for different pairs of tool and workpiece Several researchers applied this method in the investigation of cutting force in the face milling process of SKD61 Hard Steel [1], flat milling process of aerospace aluminum alloys [2], ball milling graded material [3], and so on. The modeling process was started from the analysis of the metal cutting principle that was the essence of cutting processes; so, this method had been widely applied in cutting processes such as turning, milling, drilling, etc. The reviews of this method are presented in the following
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