Abstract
Turn-milling is regarded as the milling of a curved surface while rotating the workpiece around its center point, which combines effectively the advantages of both turning and milling, wherein it allows for good metal removal with the difficult-to-cut thin-walled workpieces in aviation. The objective of the present work is to study cutting force by turn-milling in cutting condition. Aiming at the deformation properties of thin-walled blade, the predicted models of rigid cutting force and flexible cutting force with ball cutter are provided, respectively, in turn-milling process. The deformation values of blade and cutter are calculated, respectively, based on the engaged trajectory by using the iterative algorithm. The rigid and flexible cutting forces are compared and the influence degrees of cutting parameters on cutting forces are analyzed. These conclusions provide theoretical foundation and reference for turn-milling mechanism research.
Highlights
As a newly emerging cutting technology, turn-milling makes use of the advantages of turning and milling, in which both workpiece and cutting tool are given rotary motion simultaneously
The machining accuracy and processing efficiency are obtained by the advanced machining method
With the rapid development of processing technology, the new machining techniques are well used to demand the requirements of product complexity and production of high-efficiency [1,2,3]
Summary
As a newly emerging cutting technology, turn-milling makes use of the advantages of turning and milling, in which both workpiece and cutting tool are given rotary motion simultaneously. Budak et al [13,14,15,16,17] have proposed that the variable pitch cutters can be used to calculate cutting force in milling of these extremely flexible components They have studied the notion that the workpiece dynamics affect milling force in machining of flexible parts and presented a methodology for prediction of in-process workpiece dynamics based on a structural dynamic modification by using the FE model of the workpiece. Herranz et al in [18] have proposed a working methodology for efficient process planning, based on the previous analysis of those static and dynamic phenomena that may happen during high-speed cutting This methodology includes (1) several steps in order to minimize the bending and vibration effects, (2) optimal monitoring methods to detect process instability, and (3) description of the best way for the tuning of cutting conditions and chip load, by means of simulation at different machining stages.
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