Abstract
Under most processing conditions, the milling force is expected to be stable and not to fluctuate, in order to improve the processing quality. This study focuses on analyzing the force fluctuation characteristics under conditions of different processing and cutter parameters. An original model is proposed to predict the force fluctuation during the milling process of a helical-edge cutter. At the same time, three force fluctuation characteristics related to the axial cutting depth and cutter parameters are determined: uniformity, periodicity and symmetry. The corresponding mathematical derivation and proof method are given for the first time through a force transformation of projecting the superposition chip thickness on a virtual cutting edge. On this basis, a fast estimation method and an accurate simulation method for force fluctuation prediction are established to quantify the intensity of force fluctuations under different parameters. Both two prediction methods and the experimental cutting tests validate the proposed theory effectively. The result shows a high potential of the proposed theory for studying the force behavior under different milling parameters or cutter parameters and at least 75% of the test workload can be reduced.
Highlights
The milling cutter of a helical-edge has been widely used in high-speed and highprecision manufacturing, especially in side milling
According to Equation (24), the milling force is symmetrical on the axial depth of cut Apoc /2 and the output symmetry axis is C0 /2
This study presents three characteristics of milling force fluctuations: uniformity, periodicity and symmetry
Summary
The milling cutter of a helical-edge has been widely used in high-speed and highprecision manufacturing, especially in side milling. The previous studies have considered the effects of individual changes in each parameter on force characteristics, the mathematical relationship between various parameters and the intensity of milling force fluctuation, such as combined changes in the axial depth of cut, helix angle and tool radius, have still not been revealed and explained clearly. It is shown that when the proposed theory is applied, the milling test needs only 25% of the axial depth of cut to reveal the characteristics of force fluctuation at all cut depths This proves that the proposed theory can significantly reduce the test workload in a milling force experiment and can be used in the experimental research of milling force behavior.
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