Abstract
The current challenge in metal cutting models is to estimate cutting forces in order to achieve a more accurate and efficient machining process simulation and optimization system. This paper presents an efficient mathematical model for process simulation to evaluate the cutting action with variable part geometries of helical cutters and predict the cutting forces involved in the process. The objective of this paper has been twofold: to improve both the accuracy and computational efficiency of the algorithm for cutting force estimation in peripheral milling. Runout effect and the real tool tooth trajectory are taken into account to determine the instantaneous position of the cutting flute. An expression of average chip thickness for the engaged flute in the cut is derived for cutting force calculations resulting in a more efficient process simulation method in comparison with previous models. It provides an alternative to other studies in scientific literature commonly based on numerical integration. Experiments were carried out to verify the validity of the proposed method.
Highlights
An ever more demanding machining industry requires better accuracy and higher productivity
This paper presents an efficient mathematical model for process simulation to evaluate the cutting action with variable part geometries of helical cutters and predict the cutting forces involved in the process
Machining processes can be improved by strengthening the capacity to predict cutting process performance, which is often needed for automation or optimization of machining processes
Summary
An ever more demanding machining industry requires better accuracy and higher productivity. In their study about stability in milling, Jin et al [17] pointed out the loss of accuracy when a discretized cutting flute is used to estimate the cutting forces; they used an analytical method instead Another problem which arises from modelling is that the mechanics of milling processes and chip generation are well established when they are oriented to steady-state cutting processes, cutter-workpiece intersection domains are not so simple to determine when transient states are issued. This is achieved by means of a cutting force estimation model based on closed form expressions, in an attempt to avoid numerical integration This procedure allows for the possibility of extending research topics into other areas of interest within the general framework of machining processes
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callDisclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
