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A new analytical ICCE and force prediction model for wide-row machining of free-form surface

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Abstract

Cutting force is the most intuitive reflection of various influencing factors in the milling process, which is important for improving machining quality and efficiency. For the wide-row milling with flat-end mill of free-form surface, an analytical in-cut cutting edge (ICCE) algorithm is studied in detail, and overall cutting force model is further constructed. The cutter location points along tool path are discretized into small oblique planes. Taking the oblique plane machining as the new object, the relative position of flat-end mill and workpiece in five-axis machining is defined parametrically. By constructing a semi-enclosed space in which the cutting edge participates in cutting, the ICCE is directly obtained. By analyzing the cutting force of oblique plane, the cutting force model of free-form surface can be established by spatial coordinate transformation. The simulation and experiment have demonstrated the correctness and effectiveness of the proposed ICCE algorithm and force prediction model.

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Abbreviations

a :

Matrix element

a :

Cutter axis

d n :

Cutting depth

d z :

Axial height of cutting edge element

f :

Feed direction

f z :

Feed per tooth

F c :

Cutting force in cutter coordinate system

F w :

Cutting force in workpiece coordinate system

h :

Undeformed cutting layer thickness

H :

Cutting dividing plane

K tc :

Ratio coefficient of tangential cutting force

K rc :

Ratio coefficient of raidal cutting force

K ac :

Ratio coefficient of axial cutting force

M :

Auxiliary surface

n :

Normal direction

N :

Cutting edges

O :

Origin point

P(x 0, y 0, z 0):

Cutting edge element point

R :

Cutter radius

s :

Step distance

s :

Xc axis vector

T f :

Transformation matrix

U :

Sweep surface

V :

Unmachined surface

X c :

Coordinate system axis

Y c :

Coordinate system axis

Z c :

Coordinate system axis

(x s, y s, z s):

Workpiece surface point

β :

Helix angle

ε :

Feed deflection angle

γ :

Plane tilt angle

ϕ :

Radial position angle

Δ :

Judgment condition

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Acknowledgments

This research is supported by the National Natural Science Foundation of China No. 52075076, No. 52005078 and No. U1908231.

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Authors and Affiliations

  1. Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian, 116024, P.R. China

    Minglong Guo, Zhaocheng Wei, Jia Wang, Minjie Wang, Xiaoyu Wang & Shengxian Liu

Authors
  1. Minglong Guo
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  2. Zhaocheng Wei
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  3. Jia Wang
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  4. Minjie Wang
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  5. Xiaoyu Wang
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  6. Shengxian Liu
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Corresponding author

Correspondence to Zhaocheng Wei.

Additional information

Zhaocheng Wei is an Associate Professor, School of Mechanical Engineering, Dalian University of Technology, China. He has hosted and participated in the National Natural Science Foundation of China for many times. His research focuses on theory of cutting, cryogenic cutting, mechanics and dynamics of cutting, non-standard tool design and optimization.

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Guo, M., Wei, Z., Wang, J. et al. A new analytical ICCE and force prediction model for wide-row machining of free-form surface. J Mech Sci Technol 37, 7–16 (2023). https://doi.org/10.1007/s12206-022-1202-7

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  • DOI: https://doi.org/10.1007/s12206-022-1202-7

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