A closed form mechanistic cutting force model for helical peripheral milling of ductile metallic alloys |
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| Authors: | Abhijit Bhattacharyya John K. Schueller Brian P. Mann John C. Ziegert Tony L. Schmitz Fred J. Taylor Norman G. Fitz-Coy |
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| Affiliation: | 1. Department of Mechanical & Aerospace Engineering, University of Florida, Gainesville, FL 32611, USA;2. Department of Mechanical Engineering and Materials Science, Duke University, Durham, NC 27708, USA;3. Department of Mechanical Engineering, Clemson University, Clemson, SC 29634, USA;4. Department of Computer and Information Science and Engineering, University of Florida, Gainesville, FL 32611, USA;1. The Key Laboratory of Contemporary Design and Integrated Manufacturing Technology, Ministry of Education, Northwestern Polytechnical University (NPU), Xi''an, Shaanxi, 710072, People''s Republic of China;2. State Key Laboratory of Mechanical Transmission, College of Mechanical Engineering, Chongqing University, Chongqing, 400044, People''s Republic of China;3. Department of Mechanical Engineering, National University of Singapore, 9 Engineering Drive 1, 117576, Singapore;1. National NC System Engineering Research Center, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China;2. State Key Laboratory of Digital Manufacturing Equipment and Technology, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China |
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| Abstract: | A closed form mechanistic model is developed for cutting forces in helical peripheral milling (endmilling) of ductile metallic alloys. This paper presents an alternative derivation, using the frontal chip area, to describe two series of cutting force expressions—one using a Heaviside unit step function and the other using a Fourier series expansion. A specific advantage of the present work is highlighted by deriving analytical expressions for sensitivity coefficients required to analytically propagate the uncertainty in the cutting-force model parameters. Another advantage is that even very small radial immersions can be used to derive cutting coefficients reliably, along with their variances. The aforementioned analytical investigations are applied to a series of experimental cutting tests to estimate the force-model cutting coefficients. Experimental investigations include the study of a tool having radial runout. Finally, confidence intervals are placed on predicted forces which experimentally verify the validity of the proposed force model. |
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