Analytical Cutting Forces Model of Helical Milling Operations
Helical milling operations are used to generate or
enlarge boreholes by means of a milling tool. The bore diameter can be
adjusted through the diameter of the helical path. The kinematics of
helical milling on a three axis machine tool is analysed firstly. The
relationships between processing parameters, cutting tool geometry
characters with machined hole feature are formulated. The feed motion
of the cutting tool has been decomposed to plane circular feed and
axial linear motion. In this paper, the time varying cutting forces acted
on the side cutting edges and end cutting edges of the flat end cylinder
miller is analysed using a discrete method separately. These two
components then are combined to produce the cutting force model
considering the complicated interaction between the cutters and
workpiece. The time varying cutting force model describes the
instantaneous cutting force during processing. This model could be
used to predict cutting force, calculate statics deflection of cutter and
workpiece, and also could be the foundation of dynamics model and
predicting chatter limitation of the helical milling operations.
[1] R. Iyer, P. Koshy, and E. Ng, "Helical milling: An enabling technology
for hard machining precision holes in AISI D2 tool steel," International
Journal of Machine Tools & Manufacture, vol. 47, no. 2, pp. 205-210,
Feb. 2007.
[2] B. Denkena, D. Boehnke, and J.H. Dege, "Helical milling of
CFRP-titanium layer compounds," CIRP Journal of Manufacturing
Science and Technology, vol. 1, no. 2, pp. 64-69, Mar. 2008.
[3] H. Sasahara, M. Kawasaki, and M. Tsutsumi, "Helical Feed Milling with
MQL for Boring of Aluminum Alloy," Transactions of the Japan Society
of Mechanical Engineer, Part C, vol. 69, no. 8, pp. 2156-2161. Aug.
2003.
[4] Y. Altintas, Manufacturing Automation: Principles of Metal Cutting and
machine Tool Vibrations (Book style). New York, US: Cambridge
University Press, 2000, pp. 41-46.
[5] B.K. Fussell, R.B. Jerard, and J.G. Hemmett, "Modeling of cutting
geometry and forces for 5-axis sculptured surface machining,"
Computer-Aided Design, vol. 35, no. 4, pp. 333-346, Mar. 2003.
[6] E. Ozturk, and E. Budak, "Modeling of 5-axis milling processes,"
Machining Science and Technology: An International Journal, vol. 11,
no. 3, pp. 287 - 311, Feb. 2007.
[7] Y. Altintas, and J.H. Ko, "Chatter stability of plunge milling," CIRP
Annals-Manufacturing Technology, vol. 55, no. 1, pp. 361-364, Jan.
2006.
[8] J.H. Ko, and Y. Altintas, "Dynamics and stability of plunge milling
operations," Journal of Manufacturing Science and Engineering-
Transactions of the ASME, vol. 129, no. 1, pp. 32-40, Jan. 2007.
[9] J.H. Ko, and Y. Altintas, "Time domain model of plunge milling
operation," International Journal of Machine Tools & Manufacture, vol.
47, no. 9, pp. 1351-1361, Jul. 2007.
[10] M. Pirtini, and I. Lazoglu, "Forces and hole quality in drilling,"
International Journal of Machine Tools & Manufacture, vol. 45, no. 11,
pp. 1271-1281, Sep. 2005.
[11] J.C. Roukema, and Y. Altintas, "Generalized modeling of drilling
vibrations. Part I: Time domain model of drilling kinematics, dynamics
and hole formation," International Journal of Machine Tools &
Manufacture, vol. 47, no. 9, pp. 1455-1473, Aug. 2007.
[12] M. Shatla, and T. Altan, "Analytical modeling of drilling and ball end
milling," Journal of Materials Processing Technology, vol. 98, no. 1, pp.
125-133, Jan. 2000.
[13] M. Elhachimi, S. Torbaty, and P. Joyot, "Mechanical modelling of high
speed drilling. 1: predicting torque and thrust," International Journal of
Machine Tools & Manufacture, vol. 39, no. 4, pp. 553-568, Mar. 1999.
[14] R.F. Hamade, C.Y. Seif, and F. Ismail, "Extracting cutting force
coefficients from drilling experiments," International Journal of
Machine Tools & Manufacture, vol. 46, no. 3-4, pp. 387-396. Apr. 2006.
[1] R. Iyer, P. Koshy, and E. Ng, "Helical milling: An enabling technology
for hard machining precision holes in AISI D2 tool steel," International
Journal of Machine Tools & Manufacture, vol. 47, no. 2, pp. 205-210,
Feb. 2007.
[2] B. Denkena, D. Boehnke, and J.H. Dege, "Helical milling of
CFRP-titanium layer compounds," CIRP Journal of Manufacturing
Science and Technology, vol. 1, no. 2, pp. 64-69, Mar. 2008.
[3] H. Sasahara, M. Kawasaki, and M. Tsutsumi, "Helical Feed Milling with
MQL for Boring of Aluminum Alloy," Transactions of the Japan Society
of Mechanical Engineer, Part C, vol. 69, no. 8, pp. 2156-2161. Aug.
2003.
[4] Y. Altintas, Manufacturing Automation: Principles of Metal Cutting and
machine Tool Vibrations (Book style). New York, US: Cambridge
University Press, 2000, pp. 41-46.
[5] B.K. Fussell, R.B. Jerard, and J.G. Hemmett, "Modeling of cutting
geometry and forces for 5-axis sculptured surface machining,"
Computer-Aided Design, vol. 35, no. 4, pp. 333-346, Mar. 2003.
[6] E. Ozturk, and E. Budak, "Modeling of 5-axis milling processes,"
Machining Science and Technology: An International Journal, vol. 11,
no. 3, pp. 287 - 311, Feb. 2007.
[7] Y. Altintas, and J.H. Ko, "Chatter stability of plunge milling," CIRP
Annals-Manufacturing Technology, vol. 55, no. 1, pp. 361-364, Jan.
2006.
[8] J.H. Ko, and Y. Altintas, "Dynamics and stability of plunge milling
operations," Journal of Manufacturing Science and Engineering-
Transactions of the ASME, vol. 129, no. 1, pp. 32-40, Jan. 2007.
[9] J.H. Ko, and Y. Altintas, "Time domain model of plunge milling
operation," International Journal of Machine Tools & Manufacture, vol.
47, no. 9, pp. 1351-1361, Jul. 2007.
[10] M. Pirtini, and I. Lazoglu, "Forces and hole quality in drilling,"
International Journal of Machine Tools & Manufacture, vol. 45, no. 11,
pp. 1271-1281, Sep. 2005.
[11] J.C. Roukema, and Y. Altintas, "Generalized modeling of drilling
vibrations. Part I: Time domain model of drilling kinematics, dynamics
and hole formation," International Journal of Machine Tools &
Manufacture, vol. 47, no. 9, pp. 1455-1473, Aug. 2007.
[12] M. Shatla, and T. Altan, "Analytical modeling of drilling and ball end
milling," Journal of Materials Processing Technology, vol. 98, no. 1, pp.
125-133, Jan. 2000.
[13] M. Elhachimi, S. Torbaty, and P. Joyot, "Mechanical modelling of high
speed drilling. 1: predicting torque and thrust," International Journal of
Machine Tools & Manufacture, vol. 39, no. 4, pp. 553-568, Mar. 1999.
[14] R.F. Hamade, C.Y. Seif, and F. Ismail, "Extracting cutting force
coefficients from drilling experiments," International Journal of
Machine Tools & Manufacture, vol. 46, no. 3-4, pp. 387-396. Apr. 2006.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:50531", author = "Changyi Liu and Gui Wang and Matthew Dargusch", title = "Analytical Cutting Forces Model of Helical Milling Operations", abstract = "Helical milling operations are used to generate or
enlarge boreholes by means of a milling tool. The bore diameter can be
adjusted through the diameter of the helical path. The kinematics of
helical milling on a three axis machine tool is analysed firstly. The
relationships between processing parameters, cutting tool geometry
characters with machined hole feature are formulated. The feed motion
of the cutting tool has been decomposed to plane circular feed and
axial linear motion. In this paper, the time varying cutting forces acted
on the side cutting edges and end cutting edges of the flat end cylinder
miller is analysed using a discrete method separately. These two
components then are combined to produce the cutting force model
considering the complicated interaction between the cutters and
workpiece. The time varying cutting force model describes the
instantaneous cutting force during processing. This model could be
used to predict cutting force, calculate statics deflection of cutter and
workpiece, and also could be the foundation of dynamics model and
predicting chatter limitation of the helical milling operations.", keywords = "Helical milling, Hole machining, Cutting force, Analytical model, Time domain", volume = "5", number = "11", pages = "2137-6", }