An Overview of Modeling and Simulation of the Milling Process
01 May 1991-Journal of Engineering for Industry (American Society of Mechanical Engineers Digital Collection)-Vol. 113, Iss: 2, pp 169-175
About: This article is published in Journal of Engineering for Industry.The article was published on 1991-05-01. It has received 413 citations till now. The article focuses on the topics: Deflection (engineering) & Machining.
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TL;DR: In this paper, the authors compared the mechanistic and unified mechanics of cutting approaches to the prediction of forces in milling operations and showed that the milling force coefficients for all force components and cutter geometrical designs can be predicted from an orthogonal cutting data base and the generic oblique cutting analysis for use in the predictive mechanistic milling models.
Abstract: The mechanistic and unified mechanics of cutting approaches to the prediction of forces in milling operations are briefly described and compared. The mechanistic approach is shown to depend on milling force coefficients determined from milling tests for each cutter geometry. By contrast the unified mechanics of cutting approach relies on an experimentally determined orthogonal cutting data base (i.e., shear angle, friction coefficient and shear stress), incorporating the tool geometrical variables, and milling models based on a generic oblique cutting analysis. It is shown that the milling force coefficients for all force components and cutter geometrical designs can be predicted from an orthogonal cutting data base and the generic oblique cutting analysis for use in the predictive mechanistic milling models. This method eliminates the need for the experimental calibration of each milling cutter geometry for the mechanistic approach to force prediction and can be applied to more complex cutter designs. This method of milling force coefficient prediction has been experimentally verified when milling Ti 6 Al 4 V titanium alloy for a range of chatter, eccentricity and run-out free cutting conditions and cutter geometrical specifications.
640 citations
TL;DR: A review of the main developments in cutting technology since the foundation of CIRP over fifty years ago is given in this paper, where the main technological developments associated with the cutting tool and tool materials, the workpiece material, the machine tool, the process conditions and the manufacturing environment are given detailed consideration.
624 citations
TL;DR: In this article, the problem of predicting stability in interrupted cutting is solved by matching the free response with an approximate solution that is valid white the tool is cutting, which can be used to predict stability for arbitrary times in the cut; the current method is applicable only to a single degree of freedom.
Abstract: Chatter in milling and other interrupted cutting operations occurs at different combinations of speed and depth of cut from chatter in continuous cutting. Prediction of stability in interrupted cutting is complicated by two facts: (1) the equation of motion when cutting is not the same as the equation when the tool is free; (2) no exact analytical solution is known when the tool is in the cut. These problems are overcome by matching the free response with an approximate solution that is valid white the tool is cutting. An approximate solution, not restricted to small times in the cut, is obtained by the application of finite elements in time. The complete, combined solution is cast in the form of a discrete map that relates position and velocity at the beginning and end of each element to the corresponding values one period earlier. The eigenvalues of the linearized map are used to determine stability. This method can be used to predict stability for arbitrary times in the cut; the current method is applicable only to a single degree of freedom. Predictions of stability for a 1-degree of freedom case are confirmed by experiment.
379 citations
TL;DR: In this paper, the dynamic stability of the milling process is investigated through a single degree of freedom mechanical model and two alternative analytical methods are introduced, both based on finite dimensional discrete map representations of the governing time periodic delay differential equation.
Abstract: The dynamic stability of the milling process is investigated through a single degree of freedom mechanical model. Two alternative analytical methods are introduced, both based on finite dimensional discrete map representations of the governing time periodic delay-differential equation. Stability charts and chatter frequencies are determined for partial immersion up- and down-milling, and for full immersion milling operations. A special duality property of stability regions for up- and down-milling is shown and explained.
298 citations
TL;DR: In this paper, the authors apply receptance coupling substructure analysis to the prediction of the tool point dynamic response, combining frequency response measurements of individual components through appropriate connections to determine assembly dynamics using simple vector manipulations.
290 citations
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...HSM simulations have included numerical time-domain methods and analytical solutions for the nonlinear, quasi-periodic regenerative process stability [3,4,8, 13-16 ]....
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...An analytical solution may be selected (e.g., [15,17-20]) or time-domain techniques may be used [3,9, 13 ,14]....
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