An investigation of cutting forces in machining with worn ball-end mill |
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| Authors: | M. Ben Said K. Saï W. Bouzid Saï |
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| Affiliation: | 1. Industrial and Enterprise Systems Engineering, University of Illinois at Urbana-Champaign, Urbana, IL, United States;2. Industrial and Systems Engineering, and Public Policy, University of Southern California, Los Angeles, CA, United States;3. Mechanical Engineering and Engineering Science, University of North Carolina at Charlotte, Charlotte, NC, United States;1. Laboratory for Machine Tools and Manufacturing Engineering, Aristoteles University of Thessaloniki, Thessaloniki, Greece;2. Fraunhofer Project Center Coatings in Manufacturing, Centre for Research and Technology Hellas, Thessaloniki, Greece, and Fraunhofer Institute for Production Technology, Aachen, Germany;3. R&D Materials and Technology Development, Seco Tools AB, Fagersta, Sweden;4. Institute for Manufacturing Technology and Production Systems, University of Kaiserslautern, Kaiserslautern, Germany;5. GFE – Gesellschaft für Fertigungstechnik und Entwicklung Schmalkalden e.V., Schmalkalden, Germany;6. Institute of Machining Technology, Technical University Dortmund, Dortmund, Germany;7. Institute of Production Engineering and Machine Tools, Leibniz Universität Hannover, Hannover, Germany;8. Rapid Product Development Laboratory, Stellenbosch University, Stellenbosch, South Africa;9. Pratt & Whitney Canada Corp., Longueuil, Quebec, Canada;10. Institute of Manufacturing Technology and Quality Management, University of Magdeburg, Magdeburg, Germany;11. Laboratory for Machine Tools and Production Engineering (WZL), RWTH Aachen University, Aachen, Germany;12. Rutgers State University of New Jersey, Piscataway, NJ, United States;13. Arts et Metiers ParisTech, LaBoMaP, Cluny, France;14. Laboratory for Tribology and Systems Dynamics, ENISE, Saint-Etienne, France;15. wbk Institute of Production Science, Karlsruhe Institute of Technology, Karlsruhe, Germany;p. Department of Management and Production Engineering, Politecnico di Torino, Turin, Italy;q. TechSolve, Inc., Cincinnati, OH, United States;r. inspire AG, Zurich, Switzerland;s. Institute for Machine Tools and Factory Management, Technische Universität Berlin, Berlin, Germany;t. Research Centre for Manufacturing Technology, Czech Technical University in Prague, Czech Republic;1. Precision Controls Laboratory, University of Waterloo, Waterloo, ON, Canada;2. Manufacturing and Automation Research Center, Koç University, Istanbul, Turkey;3. Mitsubishi Electric Research Laboratories, 201 Broadway, Cambridge, MA, USA;1. Snecma, Etablissement d’Evry-Corbeil, Rue Henri Auguste Desbruère, 91003 Evry cedex, France;2. Université de Lyon, ENISE, LTDS CNRS UMR 5513, 58 rue Jean Parort, 42023 Saint-Etienne, France;3. Université de Lyon, INSA-Lyon, MATEIS CNRS UMR 5510, 7 avenue Jean Capelle, 69621 Villeurbanne, France |
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| Abstract: | Reliable tool wear monitoring technique is one of the important aspects for achieving an integrated and self-adjusting manufacturing system. In this study, an analytical model is proposed to estimate the cutting forces, the tool geometry, and the chip geometry in relation to the flank wear, when milling with a ball-end mill. Modeling is based on thermomechanical modelling of oblique cutting. The worn tool geometry is decomposed into a series of axial elementary cutting edges. At any active tooth element, the flank wear geometry is calculated and the chip formation is obtained from an oblique cutting process characterised by local undeformed chip section and local cutting angles. Coated carbide ball-end tool, and a titanium workpiece material have been considered in this paper. The results found by using developed models have shown good agreement with experimental results. |
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