Milling Force Simulation Research Articles

Research on Modeling of Variable Milling Force Coefficient for Ruled Surface in Flank Milling Process

While considering the ruled surface geometry characteristics and its effect on milling force, the expression of variable start and exit radial immersion angles and axial cutter position are proposed through the analysis of contact area between cutter and workpiece in the flank milling process. The variable milling force coefficient model is established, and its result can be variable with the change of the curvature radius. The experimental analysis and solving results of the model are proposed. At last, the variable milling force coefficient model is verified by a flank milling force simulation result.

Analysis to Milling Force Base on AdvantEdge Finite Element Analysis

Aiming at NC milling processing simulation problem, a ball-end cutter milling force model is established, the numerical simulation analysis of aluminum alloy AL2024 milling process is conducted by using the finite element analysis software AdvantEdge finite element analysis. Focus on the Milling force simulation, the size of the milling force is obtained by simulating calculation. Using the same cutting parameters for milling experiment, the results show that simulation analysis of the cutting force values ​​are in good agreement with the experimental results，the milling force model prior established is correct. The research laid a foundation for the perfect CNC milling simulation system.

Analysis on Milling Force Based on AdvantEdge FEM

Aiming at NC milling processing simulation problem, a ball-end cutter milling force model is established, the numerical simulation analysis of aluminum alloy AL2024 milling process is conducted by using the finite element analysis software AdvantEdge FEM. Focus on the Milling force simulation, the size of the milling force is obtained by simulating calculation. Using the same cutting parameters for milling experiment, the results show that simulation analysis of the cutting force values are in good agreement with the experimental results，the milling force model prior established is correct. The research laid a foundation for the perfect CNC milling simulation system.

Research on Modeling of Ball-End Cutter for Virtual NC Machining

In this paper, a new mathematical model and modeling method of ball-end milling cutter which satisfies the request of physical simulation in virtual NC machining system are proposed. The accurate expressions of the cutting edge are presented. The precise functional surface model of ball-end cutter is developed. And the 3-D visualization for ball-end milling cutter in virtual NC machining is implemented. The model can provide necessary and accurate geometric information for physical simulation and has been applied in milling force simulation. It laid the foundation for integration of geometric simulation and physical simulation.

An Approach to Theoretical Modeling and Simulation of Face Milling Forces

A new approach to theoretical modeling and simulation of face milling forces is presented. The present approach is based on a predictive machining theory in which machining characteristic factors in continuous cutting with a single-point cutting tool can be predicted from the workpiece material properties, tool geometry, and cutting conditions. The action of a milling cutter is considered as the simultaneous work of a number of single-point cutting tools, and the milling forces are predicted from input data of workpiece material properties, cutter parameters and tooth geometry, cutting condition, cutter and workpiece vibration structure parameters, and types of milling. A predictive force model for face milling is developed using this approach. In the model, the workpiece material properties are considered as functions of strain, strain rate, and temperature. The ratio of cutter tooth engagement over milling is taken into account for the determination of temperature in the cutting region. Cutter runout is included in the modeling for the chip load. The relative displacement between the cutter and workpiece due to the cutter and workpiece vibration is also included in the modeling to consider the effect on the undeformed chip thickness. A milling force simulation system has been developed using the model, and face milling experimental tests have been conducted to verify the simulation system. It is shown that the simulation results agree well with experimental results.

Theoretical modelling and simulation of milling forces

Predictions of the forces in milling are often needed in order to establish automation or optimisation of the machining processes. A theoretical model for forces in milling based on a predictive machining theory and the mechanics of milling has been developed and is presented in this paper. In the model, the action of a milling cutter is considered as the simultaneous work of a number of single-point cutting tools, and milling forces are predicted from input data of the workpiece material properties, the cutter parameters and tooth geometry, the cutting condition, and the types of milling. The workpiece material properties are considered as functions of strain, strain rate and temperature, and the calculations for cutting temperature take account of the ratio of cutter teeth engagement over milling. Using the model, a Windows-based theoretical milling force simulation system has been developed. The system reads the input data through the menu of its dialogue box for data entry, then conducts milling simulation using the theoretical model and outputs milling force variation against cutter rotation in either numerical or graphical form. Milling experimental tests were conducted to verify the simulation system, the simulation results agreeing well with the experimental results.