Modified power prediction model based on infinitesimal cutting force during face milling process

• Xiaona Luan
• Song Zhang
• Gang Li
Regular Paper

Abstract

Nowadays soaring energy price, increasing environmental concerns, and stringent legislations make energy saving very emergency and helpful both for enterprises and environment. To deal with these issues, this paper presents a generalized mathematical power prediction model of face milling process used in manufacturing. An attempt was made to develop a relatively precise and direct power consumption model to help researchers make power optimization much easier and more practical than before. First, an infinitesimal cutting force model was proposed based on theoretical and experimental foundations. Secondly, relationship between power consumption and cutting force components was revealed, and power consumption based on infinitesimal cutting forces during metal removal process was developed. Finally, the proposed model was experimentally verified by comparing predicted and measured power consumption. Both average and instantaneous values of power consumption were used to analyze prediction error of the model. This proposed model can be used to evaluate and optimize cutting power consumption once cutting parameters were decided based on minimal energy demand. Results showed that the mean errors of maximum power and mean power were 0.076% and 0.208%, respectively. Otherwise, this proposed model will drive the field of power consumption simulation development.

Keywords

Infinitesimal cutting force Metal removal process Power prediction model

Nomenclature

dA

Cutting area of infinitesimal cutting edge (mm2)

db

Width of cutting edge element (mm)

dz

Thickness of infinitesimal cutting edge (mm)

dFc

Cutting force component normal to the tool rake (N)

dFt

Cutting force component tangential to the elementary cutting edge (N)

dFn

Fv

Cutting force component along cutting speed vc (N)

fz

Feed per tooth of the milling parameters (mm/tooth)

Ktc, Knc, Kcc

Cutting force coefficients (N/mm2)

Kte, Kne, Kce

Edge force coefficients (N/mm)

Pa-f

Additional power loss of feed drive system in cutting state (W)

Pa-n

Additional power loss of main drive system in cutting state (W)

Pc

Total cutting power consumption of experiment (W)

Pc-idle

Spindle motor’s power consumption of the auxiliary components in cutting state (W)

Pidle

Spindle motor’s power consumption of the auxiliary components in idling state (W)

Pservo

Feed motion power consumption in cutting state (W)

Pspindle

Total spindle rotational power in cutting state (W)

Premove

Total power consumption of material removing process (W)

Pu

Unload power of servo motor in feed motion system in stand-by state (W)

r

The radius of face miller (mm)

t0

Chip thickness (mm)

vc

Cutting speed (m/min)

vf

Feeding speed (m/min)

η

ϕ(t)

The instantaneous cutting angle (°)

ϕst

Cutter entry angle (°)

ϕex

Cutter exit angle (°)

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