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An analytical cutting force model for plunge milling of Ti6Al4V considering cutter runout

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Abstract

As one of the most efficient machining methods, plunge milling has gained more attention as a promising cutting process. This strategy is often used for roughing and semi-roughing processes for the more vibration free than other cutting operations. The motivation of this paper is that the cutting forces in plunge milling differ from that in side milling for the complex cutting condition and tool geometry. In this work, a systematic and analytical cutting force prediction model considering cutter runout for plunge milling is proposed. The detailed analysis of cutting geometry is important for modeling. The precise uncut width is calculated with consideration of the cutting step. In addition, the real-time uncut chip thickness of different inserts is calculated with consideration of the effect of cutter runout. The deduced cutting force model based on the predictive model can be used in various cutting conditions in the plunge milling process. Plunge milling tests with various cutting steps are carried out to verify the proposed model with the quantitative analysis of the results. The results indicate that the simulated results show quite good agreements with the measured cutting forces, which proves the correctness and accuracy of the proposed model.

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Acknowledgements

This work is partially supported by the National Natural Science Foundation of China (51705385, 51675394, 51605353), the Hubei Province Natural Science Foundation of China (2015CFB698), the State Key Laboratory of Digital Manufacturing Equipment and Technology (DMETKF2017019), and the Fundamental Research Funds for the Central Universities (WUT: 2017-IVA-016, 2017II27GX).

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Authors and Affiliations

  1. School of Mechanical and Electronic Engineering, Wuhan University of Technology, Wuhan, 430070, China

    Kejia Zhuang & Han Ding

  2. School of Automotive Engineering, Wuhan University of Technology, Wuhan, 430070, China

    Dahu Zhu

  3. State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan, 430074, China

    Han Ding

Authors
  1. Kejia Zhuang
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  2. Dahu Zhu
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  3. Han Ding
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Correspondence to Dahu Zhu.

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Zhuang, K., Zhu, D. & Ding, H. An analytical cutting force model for plunge milling of Ti6Al4V considering cutter runout. Int J Adv Manuf Technol 94, 3841–3852 (2018). https://doi.org/10.1007/s00170-017-1078-3

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  • DOI: https://doi.org/10.1007/s00170-017-1078-3

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