Abstract
Understanding the influence of the main cutting force energy consumption of the milling cutter is the basis for prediction and control of energy and machining efficiency. The existing models of cutting force energy consumption lack variables related to milling vibration and cutter teeth errors. According to the instantaneous bias of the main profile of the milling cutter under vibration, the instantaneous cutting boundary of the cutter teeth was investigated. The energy consumption distribution of the instantaneous main cutting force of the cutter tooth was studied. The model for the energy consumption of the instantaneous main cutting force of the cutter tooth and the milling cutter were both developed. The formation of energy consumption of the dynamic main cutting force of a high energy efficiency milling cutter was researched. A method for identifying the time–frequency characteristics of the energy consumption of the main cutting force under vibration was proposed and verified by experiments.
Highlights
In order to unveil the dynamic characteristics of the energy consumption of the main cutting force of the milling cutter, the instantaneous energy consumption of the main cutting force of the milling cutter was obtained by using Equations (30) and (31), as shown in Equation (33)
In order to verify the identification method for the dynamics of the main cutting force energy consumption of the milling cutter, two sets of high-speed milling experiments were carried out, the experimental setup were the same as that in Section 4, and the process parameters in Table 2 was taken as experiment scheme 1, the process parameters in Table 3 was taken as experiment scheme 2
The results showed that the energy consumption distribution function of main cutting force of cutter teeth and milling cutter was sensitive to the changes in cutting parameters
Summary
The above methods had guiding significance for the establishment of the solution model of the energy consumption dynamic characteristics of the milling cutter’s main cutting force Because it ignored the influence of the non-straight tooth structure of the milling cutter, milling vibration, and tooth error—as well as the difference in the instantaneous cutting behavior of each tooth—there was a principal error in the calculation of cutting force energy consumption. This cannot correctly reflect the dynamic characteristics of the main cutting force energy consumption of the milling cutter. The dynamic evolution of the energy consumption of the main cutting force of milling cutter was researched and validated by experiments
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