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Modeling and analyses of helical milling process

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Abstract

A comparison between the geometry of the helical milling specialized tool and conventional end mill was firstly introduced. Furthermore, a mathematical model, in which the cutting area was divided into different cutting zones, was established to simulate the cutting depths and volume of the different cutting edges (three kinds) on specialized tool. Accordingly, a specific ratio between the volume removed by different edges and the total hole volume was derived mathematically and modeled using 3D modeling software SolidWorks. Based on the established models, the cutting depths and cutting volume ratio variation trends under different cutting parameters were analyzed. The results showed that the change rules of cutting depths were different in every cutting zone and influenced greatly by the cutting parameters. In addition, the cutting volume ratio changes with different cutting parameters, but it can only vary in a certain range due to the structure of the helical milling specialized tool. The cutting volume ratio obtained from the established model shows a good agreement with the data modeled using SolidWorks, proving that the established model is appropriate. Moreover, the undeformed chip geometry was modeled and observed using SolidWorks. The undeformed chip showed a varying geometry with different cutting parameters, and it can be optimized to obtain a good cutting condition during helical milling process.

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Authors and Affiliations

  1. Key Laboratory of Mechanism Theory and Equipment Design of Ministry of Education, Tianjin University, Tianjin, 300072, China

    Yanling Tian, Yunpeng Liu, Fujun Wang, Xiubing Jing & Dawei Zhang

  2. School of Engineering, University of Warwick, Coventry,, CV4 7AL, UK

    Yanling Tian & Xianping Liu

Authors
  1. Yanling Tian
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  2. Yunpeng Liu
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  3. Fujun Wang
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  4. Xiubing Jing
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  5. Dawei Zhang
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  6. Xianping Liu
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Correspondence to Fujun Wang.

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Tian, Y., Liu, Y., Wang, F. et al. Modeling and analyses of helical milling process. Int J Adv Manuf Technol 90, 1003–1022 (2017). https://doi.org/10.1007/s00170-016-9418-2

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  • DOI: https://doi.org/10.1007/s00170-016-9418-2

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