Skip to main content
SpringerLink
Log in

Modelling, simulation and experimental investigation of cutting forces during helical milling operations

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

Abstract

The kinematics of helical milling on a three-axis machine tool is first analysed. An analytical model dealing with time domain cutting forces is proposed in this paper. The cutting force model is established in order to accurately predict the cutting forces and torque during helical milling operations as a function of helical feed, spindle velocity, axial and radial cutting depth and milling tool geometry. The forces both on the side cutting edges and on the end cutting edges along the helical feed path are described by considering the tangential and the axial motion of the tool. The dual periodicity which is caused by the spindle rotation, as well as the period of the helical feed of the cutting tool, has been included. Both simulation and experiments have been performed in order to compare the results obtained from modelling with experiments.

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

Similar content being viewed by others

References

  1. Iyer R, Koshy P, Ng E (2007) Helical milling: an enabling technology for hard machining precision holes in AISI D2 tool steel. Int J Mach Tool Manuf 47(2):205–210

    Article  Google Scholar 

  2. Denkena B, Boehnke D, Dege JH (2008) Helical milling of CFRP—titanium layer compounds. CIRP J Manuf Sci Tech 1(2):64–69

    Article  Google Scholar 

  3. Sasahara H, Kawasaki M, Tsutsumi M (2003) Helical feed milling with MQL for boring of aluminum alloy. Trans Jpn Soc Mech Eng C 69(8):2156–2161. doi:10.1299/kikaic.69.2156

    Article  Google Scholar 

  4. Altintas Y (2000) Manufacturing automation: principles of metal cutting and machine tool vibrations. New York, Cambridge

    Google Scholar 

  5. Altintas Y, Engin S (2001) Generalized modeling of mechanics and dynamics of milling cutters. CIRP Ann Manuf Technol 50(1):25–30

    Article  Google Scholar 

  6. Liu XW, Cheng K, Webb D, Luo XC (2002) Improved dynamic cutting force model in peripheral milling. Part I: theoretical model and simulation. Int J Adv Manuf Technol 20(9):631–638

    Article  Google Scholar 

  7. Liu XW, Cheng K, Webb D, Longstaff AP, Widiyarto MH (2004) Improved dynamic cutting force model in peripheral milling. Part II: experimental verification and prediction. Int J Adv Manuf Technol 24(11–12):794–805

    Article  Google Scholar 

  8. Li HZ, Zhang WB, Li XP (2001) Modelling of cutting forces in helical end milling using a predictive machining theory. Int J Mech Sci 43(8):1711–1730

    Article  MATH  Google Scholar 

  9. Lai W, Greenway B, Faddis T (2001) Flute engagement in peripheral milling. J Mater Process Technol 117(1–2):1–8

    Article  Google Scholar 

  10. Fussell BK, Jerard RB, Hemmett JG (2003) Modeling of cutting geometry and forces for 5-axis sculptured surface machining. CAD Comput Aided Des 35(4):333–346

    Article  Google Scholar 

  11. Larue A, Altintas Y (2005) Simulation of flank milling processes. Int J Mach Tool Manuf 45(4–5):549–559

    Article  Google Scholar 

  12. Wei ZC, Wang MJ, Han XG (2010) Cutting forces prediction in generalized pocket machining. Int J Mach Tool Manuf 50(5–8):449–458

    Google Scholar 

  13. Lazoglu I, Liang SY (2000) Modeling of ball-end milling forces with cutter axis inclination. J Manuf Sci Eng Trans ASME 122(1):3–11

    Article  Google Scholar 

  14. Budak E, Ozturk E, Tunc LT (2009) Modeling and simulation of 5-axis milling processes. CIRP Ann Manuf Technol 58(1):347–350

    Article  Google Scholar 

  15. Ozturk E, Budak E (2010) Dynamics and stability of five-axis ball-end milling. J Manuf Sci Eng Trans ASME 132(2). doi:10.1115/1.4001038

  16. Gradisek J, Kalveram M, Weinert K (2004) Mechanistic identification of specific force coefficients for a general end mill. Int J Mach Tool Manuf 44(4):401–414

    Article  Google Scholar 

  17. Ko JH, Altintas Y (2007) Dynamics and stability of plunge milling operations. J Manuf Sci Eng Trans ASME 129(1):32–40

    Article  Google Scholar 

  18. Altintas Y, Ko JH (2006) Chatter stability of plunge milling. CIRP Ann Manuf Technol 55(1):361–364

    Article  Google Scholar 

  19. Ko JH, Altintas Y (2007) Time domain model of plunge milling operation. Int J Mach Tool Manuf 47(9):1351–1361

    Article  Google Scholar 

  20. Damir A, Ng EG, Elbestawi M (2011) Force prediction and stability analysis of plunge milling of systems with rigid and flexible workpiece. Int J Adv Manuf Technol 54(9–12):853–877

    Article  Google Scholar 

  21. Pirtini M, Lazoglu I (2005) Forces and hole quality in drilling. Int J Mach Tool Manuf 45(11):1271–1281

    Article  Google Scholar 

  22. de Lacalle LNL, Rivero A, Lamikiz A (2009) Mechanistic model for drills with double point-angle edges. Int J Adv Manuf Technol 40(5–6):447–457

    Article  Google Scholar 

  23. Shatla M, Altan T (2000) Analytical modeling of drilling and ball end milling. J Mater Process Technol 98(1):125–133

    Article  Google Scholar 

  24. Elhachimi M, Torbaty S, Joyot P (1999) Mechanical modelling of high speed drilling. 1: Predicting torque and thrust. Int J Mach Tool Manuf 39(4):553–568

    Article  Google Scholar 

  25. Elhachimi M, Torbaty S, Joyot P (1999) Mechanical modelling of high speed drilling. 2: Predicted and experimental results. Int J Mach Tool Manuf 39(4):569–581

    Article  Google Scholar 

  26. Hamade RF, Seif CY, Ismail F (2006) Extracting cutting force coefficients from drilling experiments. Int J Mach Tool Manuf 46(3–4):387–396

    Article  Google Scholar 

  27. Li Z, Liu Q, Peng C, Sun X (2010) Cutting force modeling and simulation for hole-making operation by helical milling. Proc SPIE 7997:799703. doi:10.1117/12.883034

    Article  Google Scholar 

  28. Wang H, Qin X, Ren C, Wang Q (2011) Prediction of cutting forces in helical milling process. Int J Adv Manuf Technol. doi:10.1007/s00170-011-3435-y

Download references

Author information

Authors and Affiliations

  1. Nanjing University of Aeronautics & Astronautics, Nanjing, Jiangsu, China

    Changyi Liu

  2. CAST CRC, School of Mechanical and Mining Engineering, The University of Queensland, Brisbane, Queensland, Australia

    Gui Wang & Matthew S. Dargusch

Authors
  1. Changyi Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Gui Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Matthew S. Dargusch
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Changyi Liu.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Liu, C., Wang, G. & Dargusch, M.S. Modelling, simulation and experimental investigation of cutting forces during helical milling operations. Int J Adv Manuf Technol 63, 839–850 (2012). https://doi.org/10.1007/s00170-012-3951-4

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-012-3951-4

Keywords

Search

Navigation