Abstract
Due to the increasing esthetic requirements and complex functional specifications of machined components, peripheral milling of curved geometries is becoming increasingly important in the aerospace, automotive, and the injection molds industries. However, one of the major difficulties encountered by manufacturers is that peripheral milling of the curved surfaces which is characterized by significant amount of engagement variation along the tool path causing a sudden change in cutting forces and consequently a deterioration of the surface roughness of the machined parts and lowers productivity. The present paper presents a two-dimensional machining model allowing the simulation of cutting forces including the cutting process damping in curvilinear peripheral milling. In the study, we attempt to analyze the effect of various milling parameters such as cutting speed, feed rate, axial and radial depth of cut, tool diameter, and tool helix angle on cutting forces generated by the peripheral milling of a curved surface profile. The cutting forces obtained through simulation model are compared with experimental results.
Similar content being viewed by others
References
Albrecht P (1965) Dynamics of the metal-cutting process. J Manuf Sci Eng 87:429–441
Cumming JD, Kobayashi S and Thomsen EG (1965) A new analysis of the forces in orthogonal metal cutting. J Manuf Sci Eng 87(4):480–486. https://doi.org/10.1115/1.3670865
Merritt HE (1965) Theory of self-excited machine-tool chatter. J. Manuf. Sci. Eng 87:447–454
Kegg RL (1965) Cutting dynamics in machine tool chatter, contribution to machine tool chatter Research-3. J Manuf Sci Eng 87:464–470
Nakayama K, Tamura K (1968) Size Effect in Metal Cutting Force. J Manuf Sci Eng. 90(1):119–126. https://doi.org/10.1115/1.3604585
Sission TR, Kegg RL (1969) An explanation of low speed chatter effects. J Manuf Sci Eng 91(4):951–958
Saravanja FN, D'Souza AF (1974) Nonlinear stability analysis of chatter in metal cutting. J Manuf Sci Eng 96(2):670–675
Pandit MS, Subramanian TL, Wu SM (1975) Stability of random vibrations with special reference to machine tool chatter. J Manuf Sci Eng. 97(1):216–219
Ismail F, Elbestawi MA, Du R, Urbasik K (1993) Generation of milled surface including tool dynamics and wear. J Manuf Sci Eng 115:245–252
Montgomery D, Altintas Y (1991) Mechanism of cutting force and surface generation in dynamic milling. J Manuf Sci Eng 113:160–168
Tlusty J (1978) Analysis of the state of research in cutting dynamics. Annals of the CIRP 27(2):583–589
Tlusty J (1986) Dynamics of high speed milling. J Manuf Sci Eng 108:59–67
Mehdi K, Rigal JF, Play D (2002a) Dynamic behavior of a thin wall cylindrical WorkPiece during the turning process part I: cutting process simulation. J Manuf Sci Eng 124(3):562–568
Mehdi K, Rigal JF, Play D (2002b) Dynamic behavior of a thin wall cylindrical WorkPiece during the turning process part II: experimental approach and validation. J Manuf Sci Eng 124(3):569–580
Gerasimenko A, Guskov M, Duchemin J, Lorong P, Gouskov A (2015) Variable compliance related aspects of chatter in turning thin-walled tubular parts. Procedia CIRP 31:58–63
Gouskov AM, Guskov M, Lorong P, Panovko G (2017) Influence of flank face on the condition of chatter self-excitation during turning. Int J Mach Mach Mater 19(1):17–40
Huang CY, Wang JJ (2007) Mechanistic modeling of process damping in peripheral milling. J Manuf Sci Eng 129:12–20
Xin L, Wei Z, Liang L, Ning H, Sheng WC (2015) Modeling and application of process damping in milling of thin-walled workpiece made of titanium alloy. Shock Vib 2015:1–12. https://doi.org/10.1155/2015/431476
Mehdi K, Zghal A (2012) Modelling cutting force including thrust and tangential damping in peripheral milling process. Int J Mach Mach Mater 12(3):236–251
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Mejri, H., Mehdi, K. Modeling of cutting forces in curvilinear peripheral milling process. Int J Adv Manuf Technol 102, 277–291 (2019). https://doi.org/10.1007/s00170-018-03249-x
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-018-03249-x