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The research of cutting force prediction for worn ball-end tool considering spring back

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Abstract

The cutting force prediction of worn tool is very important for wear state identification, tool life optimization, and machining quality improvement. The wearing force is mainly produced by the tool-workpiece contact which influenced by several factors such as the flank wear and the spring back. In this paper, the prediction of cutting force for worn ball-end tool with spring back influence is investigated. Firstly, the tool is separated into differential cutting edges and the differential cutting force is divided into shearing force computed by shearing coefficients and contacting force computed by contact stress. Considering the influence of spring back, the real contact width is applied instead of the flank wear width and a variable declining coefficient is introduced into the stress distribution function. Secondly, the cutter-workpiece engagement of base cutting process and spring back cutting process is analyzed and the cutting force is computed with the accumulation of all the engaging differential cutting forces. Then, a spring back value computation method with the measured force data of single-tooth cutting is presented. Lastly, the machining experiments are designed and carried out for parameter identification and accuracy validation. As the experimental results shows, the deviation between the average force of predicting results and the measured data is small. Comparing to the prediction without spring back, the instantaneous cutting force computed in this paper also shows better fitness and accuracy.

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Funding

This work was supported by grants from the Industry-University-Research Collaboration project of China (HFZL2020CXY014-1), the National Natural Science Foundation of China (52005030), and the Fundamental Research Funds for the Central Universities (2021RC275).

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Authors and Affiliations

  1. School of Mechanical, Electronic and Control Engineering, Beijing Jiaotong University, 100044, Beijing, People’s Republic of China

    Mingbo Zhao, Yonglin Cai, Yixuan Song & Haitong Wang

  2. Key Laboratory of Vehicle Advanced Manufacturing, Measuring and Control Technology (Beijing Jiaotong University), Ministry of Education, Beijing, China

    Yonglin Cai & Haitong Wang

  3. CRRC Qishuyan Co., Ltd., Changzhou, China

    Ninggang Wang

Authors
  1. Mingbo Zhao
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  2. Yonglin Cai
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  5. Haitong Wang
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Contributions

Mingbo Zhao proposed the method and carried out the experimental verification and result analysis. He also drafted the manuscript. Yonglin Cai and Haitong Wang discussed the study conception and experimental scheme. Ninggang Wang and Yixuan Song contributed to the scheme and implement of the experiment. All the authors commented on previous versions of the manuscript. All authors have read and approved the final manuscript.

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Correspondence to Yonglin Cai.

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Zhao, M., Cai, Y., Wang, N. et al. The research of cutting force prediction for worn ball-end tool considering spring back. Int J Adv Manuf Technol 125, 5619–5629 (2023). https://doi.org/10.1007/s00170-023-10909-0

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  • DOI: https://doi.org/10.1007/s00170-023-10909-0

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