A novel milling force model based on the influence of tool geometric parameters in end milling

Xianglei Zhang,Jing Zhang,Yan Ren,Mingming Xu,Hongming Zhou

doi:10.1177/1687814018798185

Abstract

A novel milling force model for cutting aviation aluminum alloy 7075 using carbide end mill is established in this article. A two-dimensional end-milling model is set up to investigate the influence of tool geometric parameters on milling force with the single-factor analysis. The relationship between milling forces and tool geometric parameters is obtained by nonlinear regression fitting method. Based on the existing empirical model of milling force, quadratic polynomial factor is taken into consideration to explore the influence of tool geometric parameters on milling force. Thus, a novel milling force model is built up which includes tool geometric parameters and milling parameters. The coefficients of the novel model are identified by the direct method and the loop method. The precisions of the coefficients obtained by the two methods are compared between prediction values and experiment values. After comparison, the model whose coefficients are obtained by loop method has higher prediction ability. End-milling experiments were carried out to verify the prediction accuracy of the novel milling force model. The result shows that the novel model of milling force has high accuracy in prediction. The method of building the milling force model proposed in this article can be applied to other types of milling cutter.

Highlights

Milling process has been extensively applied for die components, and aeronautical or biomedical parts made of metal alloys, such as Ti, Ni, and Al-based alloys, due to their excellent mechanical properties.[1,2]
During high-speed milling, the milling force has an important influence on the tool life, surface quality, vibration stability, cutting tool, and workpiece machining deformation
The existing milling force models were divided into following categories: empirical model, analytical model, artificial intelligence model, and finite element method.[4,5,6,7]

Summary

Introduction

Milling process has been extensively applied for die components, and aeronautical or biomedical parts made of metal alloys, such as Ti-, Ni-, and Al-based alloys, due to their excellent mechanical properties.[1,2] During high-speed milling, the milling force has an important influence on the tool life, surface quality, vibration stability, cutting tool, and workpiece machining deformation. In other words, cutting force coefficients have to be renewed whenever the geometry of cutter is changed.[16] This article is based on a two-dimensional (2D) milling simulation model of solid carbide end-mill milling aviation aluminum alloy 7075. For the convenience to carry out single-factor analysis, geometrical structure parameters of end mill in this article are 16 mm in milling cutter diameter, 0.01 mm in blunt round radius, 30° in helix angle, 15° in rake angle, and 8° in relief angle.

Results

Conclusion