A general calibration method of cutter runout and specific cutting force coefficients (SCFCs) for flat-end cutter is proposed in this paper, and a high accuracy of cutting force prediction during peripheral milling is established. In the paper, the cutter runout, the bottom-edge cutting effect, and the actual feedrate with limitation during large tool path curvature are concerned comprehensively. First, based on the trochoid motion, a tooth trajectory model is built up and an analytical instantaneous uncut chip thickness (IUCT) model is put forward for describing the cutter/workpiece engagement (CWE). Second, a noncontact identification method for cutter runout including offset and inclination is given, which constructs an objective function by using the cutting radius relative variation between adjacent teeth, and identifies through a numerical optimization method. Thirdly, with consideration of bottom-edge cutting effect, the paper details a three-step calibration procedure for SCFCs based on an enhanced thin-plate milling experiment. Finally, a series of milling tests are performed to verify the effectiveness of the proposed method. The results show that the approach is suitable for both constant and nonconstant pitch cutter, and the generalization has been proved. Moreover, the paper points out that the cutter runout has a strong spindle speed-dependent effect, the milling force in cutter axis direction exists a switch-direction phenomenon, and the actual feedrate will be limited by large tool path curvature. All of them should be considered for obtaining an accurate milling force prediction.
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February 2018
Research-Article
General Modeling and Calibration Method for Cutting Force Prediction With Flat-End Cutter
Xing Zhang,
Xing Zhang
State Key Laboratory for Manufacturing
Systems Engineering,
Xi'an Jiaotong University,
Xi'an 710054, Shaanxi Province, China
Systems Engineering,
Xi'an Jiaotong University,
Xi'an 710054, Shaanxi Province, China
Search for other works by this author on:
Wei Zhang,
Wei Zhang
State Key Laboratory for Manufacturing
Systems Engineering,
Xi'an Jiaotong University,
Xi'an 710054, Shaanxi Province, China
Systems Engineering,
Xi'an Jiaotong University,
Xi'an 710054, Shaanxi Province, China
Search for other works by this author on:
Jun Zhang,
Jun Zhang
State Key Laboratory for Manufacturing
Systems Engineering,
Xi'an Jiaotong University,
Xi'an 710054, Shaanxi Province, China
Systems Engineering,
Xi'an Jiaotong University,
Xi'an 710054, Shaanxi Province, China
Search for other works by this author on:
Bo Pang,
Bo Pang
State Key Laboratory for Manufacturing
Systems Engineering,
Xi'an Jiaotong University,
Xi'an 710054, Shaanxi Province, China
Systems Engineering,
Xi'an Jiaotong University,
Xi'an 710054, Shaanxi Province, China
Search for other works by this author on:
Wanhua Zhao
Wanhua Zhao
State Key Laboratory for Manufacturing
Systems Engineering,
Xi'an Jiaotong University,
Xi'an 710054, Shaanxi Province, China
e-mail: whzhao@xjtu.edu.cn
Systems Engineering,
Xi'an Jiaotong University,
Xi'an 710054, Shaanxi Province, China
e-mail: whzhao@xjtu.edu.cn
Search for other works by this author on:
Xing Zhang
State Key Laboratory for Manufacturing
Systems Engineering,
Xi'an Jiaotong University,
Xi'an 710054, Shaanxi Province, China
Systems Engineering,
Xi'an Jiaotong University,
Xi'an 710054, Shaanxi Province, China
Wei Zhang
State Key Laboratory for Manufacturing
Systems Engineering,
Xi'an Jiaotong University,
Xi'an 710054, Shaanxi Province, China
Systems Engineering,
Xi'an Jiaotong University,
Xi'an 710054, Shaanxi Province, China
Jun Zhang
State Key Laboratory for Manufacturing
Systems Engineering,
Xi'an Jiaotong University,
Xi'an 710054, Shaanxi Province, China
Systems Engineering,
Xi'an Jiaotong University,
Xi'an 710054, Shaanxi Province, China
Bo Pang
State Key Laboratory for Manufacturing
Systems Engineering,
Xi'an Jiaotong University,
Xi'an 710054, Shaanxi Province, China
Systems Engineering,
Xi'an Jiaotong University,
Xi'an 710054, Shaanxi Province, China
Wanhua Zhao
State Key Laboratory for Manufacturing
Systems Engineering,
Xi'an Jiaotong University,
Xi'an 710054, Shaanxi Province, China
e-mail: whzhao@xjtu.edu.cn
Systems Engineering,
Xi'an Jiaotong University,
Xi'an 710054, Shaanxi Province, China
e-mail: whzhao@xjtu.edu.cn
1Corresponding author.
Manuscript received March 31, 2017; final manuscript received October 31, 2017; published online December 18, 2017. Assoc. Editor: Jaydeep Karandikar.
J. Manuf. Sci. Eng. Feb 2018, 140(2): 021007 (18 pages)
Published Online: December 18, 2017
Article history
Received:
March 31, 2017
Revised:
October 31, 2017
Citation
Zhang, X., Zhang, W., Zhang, J., Pang, B., and Zhao, W. (December 18, 2017). "General Modeling and Calibration Method for Cutting Force Prediction With Flat-End Cutter." ASME. J. Manuf. Sci. Eng. February 2018; 140(2): 021007. https://doi.org/10.1115/1.4038371
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