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Calculation method for instantaneous shear energy efficiency and volume-energy ratio of milling cutter under multiple factors

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Abstract

The energy efficiency and volume-energy ratio of milling cutter are important index to evaluate energy utilization rate of milling cutter. The milling process is not only affected by random factors such as cutter tooth error but also by non-steady-state factors such as milling vibration and cutter tooth wear. These factors lead to the uncertainty of machining process, and it is difficult to identify energy transfer relationship of milling cutter. According to finite element simulation analysis results of milling cutter, the wear depth of cutting edge was obtained. The coordinates of selected point on cutting edge were solved, and the time varying of cutting edge equation after wear was revealed. According to the calculation method of instantaneous shear energy efficiency, volume shear energy ratio, and volume tangent-force energy ratio, the variation of energy efficiency and volume-energy ratio along the cutting edge was obtained. And temporal-spatial distribution of energy efficiency and volume-energy ratio under multiple factors was revealed. The influencing mechanism of energy efficiency and volume-energy ratio of cutter teeth was identified. A calculation method for distribution of energy efficiency and volume-energy ratio under multiple factors was proposed. The validity of the model was verified by using energy efficiency and volume-energy ratio under different cutting parameters. The results showed that above models could distinguish the influence of unsteady factors on energy efficiency and volume-energy ratio, which could provide a basic model for high-energy-efficiency design of cutter teeth.

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Abbreviations

P(t):

Input energy

P ie(t):

Energy in the milling cutter body

P ce(t):

Centrifugal energy for milling cutter

P c(t):

Tangential force energy

P c v(t):

Vibration energy for milling cutter

P s i(t):

Shear force energy

P f i(t):

Friction energy

P sv i(t):

Energy consumption for material removal

P fw i(t):

Wear energy for tooth flank

Q w(t):

Wear on the rake face

f w(t):

Wear on the cutting edge of cutter tooth

H w(t):

Wear on tool flank of cutter tooth

SEE:

Shear energy efficiency

VER:

Volume-energy ratio

VSER:

Volume shear energy ratio

VTER:

Volume tangent-force energy ratio

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Funding

This research was supported by the Heilongjiang Provincial Natural Science Foundation of China [grant number ZD2020E008]; and the National Natural Science Foundation of China [grant numbers 52105440, 51875145].

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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

    Lili Fan, Bin Jiang, Peiyi Zhao & Bin Wang

Authors
  1. Lili Fan
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  2. Bin Jiang
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  3. Peiyi Zhao
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  4. Bin Wang
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Contributions

Conceptualization, BJ and LF; methodology, BJ and LF; software, LF and BW; validation, LF; investigation, LF and BW; data curation, LF; writing—original draft preparation, LF; writing—review and editing, LF and PZ; supervision, BJ and PZ; project administration, BJ and PZ; funding acquisition, BJ and PZ. All authors have read and agreed to the published version of the manuscript.

Corresponding author

Correspondence to Bin Jiang.

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Fan, L., Jiang, B., Zhao, P. et al. Calculation method for instantaneous shear energy efficiency and volume-energy ratio of milling cutter under multiple factors. Int J Adv Manuf Technol 129, 2897–2920 (2023). https://doi.org/10.1007/s00170-023-12449-z

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