Abstract
Tool radial runout is an inevitable phenomenon which significantly affects the cutting conditions in a milling operation. Indeed, tool runout causes irregular spacing between cutter teeth creating uneven engagement conditions. This aspect may limit the accuracy and reliability of the predictive approaches dealing with important phenomena in milling such as chatter, surface errors and tool wear. For these predictions, a cutting force model, which includes tool runout, is essential, but it requires complex formulations which limit its application. This paper presents a simplified cutting force model for an endmill with generic geometry then adapts it to represent the effect of radial runout on a regular endmill. The model thus obtained expresses the cutting forces as a Fourier series considering the effect of tool runout on the cutting force frequency components, and it is easy to apply to other predictive models. The proposed formulations are validated, and an application is presented.
This is a preview of subscription content, log in via an institution to check access.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Lee KY, Kim HM, Park SS (2007) A run-out measuring method using modeling and simulation in four-fluted end milling. J Mater Process Technol 187–188:207–211
Matsumura T, Tamura S (2017) cutting force model in milling with cutter runout. In: Procedia CIRP. Elsevier B.V., pp 566–571
Zhu K, Zhang Y (2017) Modeling of the instantaneous milling force per tooth with tool run-out effect in high speed ball-end milling. Int J Mach Tools Manuf 118–119:37–48
Schmitz TL, Couey J, Marsh E, Mauntler N, Hughes D (2007) Runout effects in milling: surface finish, surface location error, and stability. Int J Mach Tools Manuf 47:841–851
Niu J, Ding Y, Zhu LM, Ding H (2017) Mechanics and multi-regenerative stability of variable pitch and variable helix milling tools considering runout. Int J Mach Tools Manuf 123:129–145
Wan M, Zhang WH, Tan G, Qin GH (2016) New algorithm for calibration of instantaneous cutting-force coefficients and radial run-out parameters in flat end milling 221:1007–1019. https://doi.org/10.1243/09544054JEM515
Wan M, Zhang WH, Dang JW, Yang Y (2009) New procedures for calibration of instantaneous cutting force coefficients and cutter runout parameters in peripheral milling. Int J Mach Tools Manuf 49:1144–1151
Chen D, Zhang X, Xie Y, Ding H (2018) Precise estimation of cutting force coefficients and cutter runout in milling using differential evolution algorithm. Procedia CIRP 77:283–286
Li G, Xian C, Xin H (2021) Identification of eccentricity for disc milling cutter of indexable two sided inserts. Adv Mech Eng 13
Chen Y, Lu J, Deng Q, Ma J, Liao X (2022) Modeling study of milling force considering tool runout at different types of radial cutting depth. J Manuf Process 76:486–503
Gao H, Shen H, Liu X, Li R (2020) Mechanics and dynamics research considering the tool radial runout effect in plunge milling. Int J Adv Manuf Technol 106:2391–2402
Kumanchik LM, Schmitz TL (2007) Improved analytical chip thickness model for milling. Precis Eng 31:317–324
Wang JJJ, Zheng CM (2003) Identification of cutter offset in end milling without a prior knowledge of cutting coefficients. Int J Mach Tools Manuf 43:687–697
Grossi N, Morelli L, Scippa A, Campatelli G (2022) A frequency-based analysis of cutting force for depths of cut identification in peripheral end-milling. Mech Syst Signal Process 171
Urbikain G, Artetxe E, López de Lacalle LN (2017) Numerical simulation of milling forces with barrel-shaped tools considering runout and tool inclination angles. Appl Math Model 47:619–636
Diez E, Perez H, Guzman M, Vizan A (2013) An improved methodology for the experimental evaluation of tool runout in peripheral milling. Int J Adv Manuf Technol 65:283–293
Jing X, Tian Y, Yuan Y, Wang F (2017) A runout measuring method using modeling and simulation cutting force in micro end-milling. Int J Adv Manuf Technol 91:4191–4201
Zhang X, Zhang J, Zhang W, Li J, Zhao W (2018) A non-contact calibration method for cutter runout with spindle speed dependent effect and analysis of its influence on milling process. Precis Eng 51:280–290
Nakatani K, Yauchi M, Matsubara A, Yamaji I (2021) Improvement of machining accuracy by measurement and adjustment of dynamic runout of end mill. Procedia CIRP 101:306–309
Krüger M, Denkena B (2012) Model-based identification of tool runout in end milling and estimation of surface roughness from measured cutting forces. Int J Adv Manuf Technol 65(5):1067–1080
Seethaler RJ, Yellowley I (1999) The identification of radial runout in milling operations. J Manuf Sci Eng 121:524–531
Herman KA, Liang SY (1997) In-process monitoring of end milling cutter runout. Mechatronics 7:1–10
Grossi N, Morelli L, Venturini G, Scippa A (2021) Forces shapes in 3-axis end-milling: classification and characteristic equations. J Manuf Mater Process 5:117. 5, 117
Yang L, DeVor RE, Kapoor SG (2005) Analysis of force shape characteristics and detection of depth-of-cut variations in end milling. J Manuf Sci Eng 127:454–462
Scippa A, Sallese L, Grossi N, Campatelli G, Scippa A, Sallese L, Grossi N, Campatelli G (2015) Improved dynamic compensation for accurate cutting force measurements in milling applications. MSSP 54:314–324
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2024 The Author(s), under exclusive license to Springer Nature Switzerland AG
About this chapter
Cite this chapter
Morelli, L., Grossi, N., Scippa, A. (2024). Milling Cutting Force Model Including Tool Runout. In: Carrino, L., Galantucci, L.M., Settineri, L. (eds) Selected Topics in Manufacturing. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-031-41163-2_8
Download citation
DOI: https://doi.org/10.1007/978-3-031-41163-2_8
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-031-41162-5
Online ISBN: 978-3-031-41163-2
eBook Packages: EngineeringEngineering (R0)