Abstract
This study has developed a model in order to predict machining forces for milling low-rigidity component with curved profile. Differing from conventional models used for straight geometries, the new model takes both the deflection of work piece-cutter system and the continuous change of curvature of machined part into account. In the model, a profile with variable curvature is defined and the feed rate per tooth on the profile is derived subsequently. The cutting force is analyzed simulatively by utilizing modified Newton–Raphson iterative algorithm. The simulative results show that the total radial deflection of workpiece–cutter system is the main factor affecting the change of cutting force. Moreover, the feed rate per tooth and its corresponding cutting force changes according to the curvature of the profile. Finally, experiments were carried out to verify the accuracy of the models.
Similar content being viewed by others
References
Ratchev S, Liu S, Huang W, Becker AA (2004) Milling error prediction and compensation in machining of low-rigidity parts. Int J Mach Tools Manuf 44(15):1629–1641
Ratchev S, Liu S, Huang W, Becker AA (2004) A flexible force model for end milling of low-rigidity parts. J Mater Process Technol 153–154:134–138
Budak E (2006) Analytical models for high performance milling. Part I: cutting forces, structural deflections and tolerance integrity. Int J Mach Tools Manuf 46:1478–1488
Rai JK, Xirouchakis P (2008) Finite element method based machining simulation environment for analyzing part errors induced during milling of thin-walled components. Int J Mach Tools Manuf 48:629–643
Kim GM, Kim BH, Chu CN (2003) Estimation of cutter deflection and form error in ball-end milling processes. Int J Mach Tools Manuf 43:917–924
Ryu SH, Lee HS, Chu CN (2003) The form error prediction in side wall machining considering tool deflection. Int J Mach Tools Manuf 43:1405–1411
Ong TS, Hinds BK (2003) The application of tool deflection knowledge in process planning to meet geometric tolerances. Int J Mach Tools Manuf 43:731–737
Xu AP, Qu YX, Zhang DW, Huang T (2003) Simulation and experimental investigation of the end milling process considering the cutter flexibility. Int J Mach Tools Manuf 43(3):283–292
Salgado MA, López de Lacalle LN, Lamikiz A, Muñoa J, Sánchez JA (2005) Evaluation of the stiffness chain on the deflection of end-mills under cutting forces. Int J Mach Tools Manuf 45:727–739
Yoon MC, Kim YG (2004) Cutting dynamic force modelling of endmilling operation. J Mater Process Technol 155–156:1383–1389
Rao VS, Rao PVM (2006) Tool deflection compensation in peripheral milling of curved geometries. Int J Mach Tools Manuf 46(15):2036–2043
Budak E, Altintas Y (1995) Modeling and avoidance of static form errors in peripheral milling of plates. Int J Mach Tools Manuf 35(3):459–476
Altintas Y, Montgomery D, Budak E (1992) Dynamic peripheral milling of flexible structures. ASME J Eng Ind 114:137–145
Elbestawi MA, Sagherian R (1991) Dynamic modeling for the prediction of surface errors in the milling of thin-walled sections. J Mater ProcTech 25:215–228
Tsai JS, Liao CL (1999) Finite-element modelling of static surface errors in the peripheral milling of thin-walled workpiece. J Mater Process Technol 94:235–246
He N, Wang ZhG, Jiang ChY, Zhang B (2003) Finite element method analysis and control stratagem for machining deflection of thin-walled components. J Mater Process Technol 139:332–336
Wan M, Zhang WH (2006) Calculations of chip thickness and cutting forces in flexible end milling. Int J Adv Manuf Technol 29:637–647
Liu ShG, Zheng L, Zhang ZH, Wen DH (2006) Optimal fixture design in peripheral milling of thin-walled workpiece. Int J Adv Manuf Technol 28:653–658
Arnaud L, Gonzalo O, Seguy S, Jauregi H, Peigné G (2011) Simulation of low-rigidity part machining applied to thin-walled structures. Int J Adv Manuf Technol 54:479–488
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Qi, H., Tian, Y. & Zhang, D. Machining forces prediction for peripheral milling of low-rigidity component with curved geometry. Int J Adv Manuf Technol 64, 1599–1610 (2013). https://doi.org/10.1007/s00170-012-4126-z
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-012-4126-z