Skip to main content
SpringerLink
Log in

Multi-scale method for recognizing damage in high-efficiency milling cutter

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Under the influence of a high-speed, interrupted-cutting impact load, the damage degree quickly increases following any structural damage in a milling cutter. The presence of structural damage must be explored given the fact that these conditions may result in irreparable and serious accidents if not immediately detected. Milling cutter damage has multi-scale characteristics. Therefore, the single-scale damage research method cannot reveal the formation and evolution of the multi-scale damage of a milling cutter, which makes it difficult to identify and control the damage of a milling cutter. The damage scales of a milling cutter are divided according to the multi-scale characteristics of milling cutter damage. Based on continuum mechanics, the dislocation theory, and molecular dynamics, the damage characterization method of the macrostructure, lattice structure, and mesoscopic structure of a milling cutter were proposed in this study. Utilizing the multi-scale finite element method and the force connection method, the loading boundary conditions of the multi-scale damage of a milling cutter were established in order to achieve a trans-scale load transfer. The damage characteristics of the macrostructure, lattice structure, and mesoscopic structure of the milling cutter were studied, and the critical value of the multi-scale damage characteristic variable of the milling cutter was obtained. Thereby, the damage position, types, and size and damage occurrence sequences of the milling cutter were revealed, and the damage formation process and the characteristics of the milling cutter were clarified. Based on this, a method for recognizing the multi-scale damage in a milling cutter was proposed and verified by experiments. The results showed that the above method could effectively identify multi-scale damage characteristics and reveal the formation and evolution process of the damage of a high-efficiency milling cutter.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24

Similar content being viewed by others

References

  1. Deng ZH, Liu ZQ, Zhang XH (2010) Research of the science and technology development in high-speed and efficient processing field. Chin J Mech Eng 46(23):106–120

    Google Scholar 

  2. Jin G, Qi HJ, Cai YJ, Zhang QC (2016) Stability prediction for milling process with multiple delays using an improved semi-discretization method. Math Method Appl Sci 39(4):949–958

    MathSciNet  MATH  Google Scholar 

  3. Budak E (2006) Analytical models for high performance milling. Part I: cutting forces, structural deformations and tolerance integrity. Int J Mach Tool Manu 46(12–13):1478–1488

    Google Scholar 

  4. Liu AM, Shen H, Kruth JP (2008) Influence of vibration characteristics of tool holder coupling on wear mechanism of back face in high speed milling. J Mech Eng 04:63–68

    Google Scholar 

  5. International Organization for Standardization (2002) ISO/T 15641–2001(E) Milling cutters for high speed machining-Safety requirements

  6. Cui XB, Zhao B, Jiao F, Ming PM (2016) Formation characteristics of the chip and damage equivalent stress of the cutting tool in high-speed intermittent cutting. Int J Adv Manuf Technol 91(5):1–11

    Google Scholar 

  7. Ma L, Xiao SF, Deng HQ, Hu WY (2014) Molecular dynamics simulation of fatigue crack propagation in bcc iron under cyclic loading. Int J Fatigue 68:253–259

    Google Scholar 

  8. Shilkrot LE, Miller RE, Curtin WA (2004) Multiscale plasticity modeling: coupled atomistics and discrete dislocation mechanics. J Mech Phys Solids 52(4):755–787

    MathSciNet  MATH  Google Scholar 

  9. Chandran KSR, Chang P, Cashman GT (2010) Competing failure modes and complex S-N curves in fatigue of structural materials. Int J Fatigue 32(3):482–491

    Google Scholar 

  10. Li J, Ren XD (2011) Multi-scale based stochastic damage evolution. Eng Fail Anal 2:726–734

    Google Scholar 

  11. Luo C, Chattopadhyay A (2011) Prediction of fatigue crack initial stage based on a multiscale damage criterion. Int J Fatigue 33(3):403–413

    Google Scholar 

  12. Zhao ZF, Chu FL (2017) Molecular dynamics simulation of crack initiation and propagation in bcc iron under load within spur gear tooth root. Fatigue Fract Eng M 41(2):323–335

    Google Scholar 

  13. Bai YL, Bai J, Li HL (2000) Damage evolution, localization and failure of solids subjected to impact loading. Int J Impact Eng 24(6–7):685–701

    Google Scholar 

  14. Tao HJ, Yin J (2007) Material design hierarchy theory and related issues across scales. Mater Sci Eng Powder Metall 12(5):264–271

    Google Scholar 

  15. Allendorf MD, Stavila V (2015) Crystal engineering, structure-function relationships, and the future of metal-organic frameworks. Crystengcomm 17(2):229–246

    Google Scholar 

  16. Leukart M, Ramm E (2003) A comparison of damage models formulated on different material scales. Comput Mater Sci 28(3–4):0–762

    Google Scholar 

  17. Kaczmarek J (2015) A method of multiscale modelling considered as a way leading to unified mechanics of materials. Acta Mech 226(5):1419–1443

    MathSciNet  MATH  Google Scholar 

  18. Bai JX, Bai QS, Tong Z (2016) Evolution of surface grain structure and mechanical properties in orthogonal cutting of titanium alloy. J Mater Res 31(24):3919–3929

    Google Scholar 

  19. Ghandehariun A, Kishawym HA, Umer U, Hussein HM (2016) Analysis of tool-particle interactions during cutting process of metal matrix composites. Int J Adv Manuf Technol 82(1):143–152

    Google Scholar 

  20. Feng Y, Wang ML, Wang BS, Hou JM (2014) Research on cutting temperature of workpiece in milling process based on WPSO. J Mech Eng 50(19):205–212

    Google Scholar 

  21. Ying L, Shi DY, Hu P, Liu WQ (2016) Numerical prediction of formability during hot forming of high strength steel based on continuum damage mechanics. Chin J Mech Eng 52(4):36–44

    Google Scholar 

  22. Li J, Fang QH, Liu YW, Zhang LC (2015) Scratching of copper with rough surfaces conducted by diamond tip simulated using molecular dynamics. Int J Adv Manuf Technol 77(5):1057–1070

    Google Scholar 

  23. Needleman A, Van de GE (2003) Discrete dislocation plasticity. Key Eng Mater 233-236(5):13–24

    MATH  Google Scholar 

  24. Zhuo XX, Liu H, Chu XH, Xu YJ (2016) A generalized multiscale finite element method for dynamic analysis of heterogeneous material. J Theor App Mech-Pol 48(02):378–386

    Google Scholar 

  25. Huang MS, Li ZH (2015) Coupled DDD-FEM modeling on the mechanical behavior of microlayered metallic multilayer film at elevated temperature. J Mech Phys Solids 85:74–97

    MathSciNet  Google Scholar 

  26. Curtin WA, Miller RE (2003) Atomistic/continuum coupling in computational materials science. Model Simul Mater Sci 11(3):33–36

    Google Scholar 

  27. Liang YC, Pen HM, Bai QS, Lu LH (2011) Multiscale simulation of nanometric cutting of single crystal cu based on bridging domain method. Acta Phys Sin-CH 60(10):30–35

    Google Scholar 

  28. Xiao SP, Belytschko T (2004) A bridging domain method for coupling continua with molecular dynamics. Comput Method Appl Mech 193(17–20):1645–1669

    MathSciNet  MATH  Google Scholar 

Download references

Funding

This work was supported by the National Natural Science Foundation of China (51875145).

Author information

Authors and Affiliations

  1. Key Laboratory of Advanced Manufacturing and Intelligent Technology, Ministry of Education, Harbin University of Science and Technology, Harbin, 150080, People’s Republic of China

    Bin Jiang, Xingliang Xu, Peiyi Zhao, Lili Fan & Yunpeng Gu

Authors
  1. Bin Jiang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Xingliang Xu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Peiyi Zhao
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Lili Fan
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Yunpeng Gu
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Peiyi Zhao.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Jiang, B., Xu, X., Zhao, P. et al. Multi-scale method for recognizing damage in high-efficiency milling cutter. Int J Adv Manuf Technol 107, 2547–2562 (2020). https://doi.org/10.1007/s00170-020-05159-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-020-05159-3

Keywords

Search

Navigation