Kinematic Analysis and Milling Force Model for Disc Milling Cutter of Indexable Inserts Considering Tool Runout

doi:10.3901/JME.2024.21.365

Abstract

Abstract: Milling force is an important cutting signal for tool state control. Milling force predict accurately can effectively sensing of tool wear. However, the technical bottleneck of the current industrial applications is that the accuracy of the milling force model cannot meet the demands of intelligent sensing, which due to the change of the insert and workbench interference mechanism under the coupling of tool runout and geometric features. A milling force mathematical model considering tool runout. Firstly, the insert geometry model under the influence of tool runout is investigated, and the actual cutting area of the insert is determined based on the geometry and microelement method. Secondly, the insert and workbench geometric interference relationship under the influence of tool runout and geometric feature coupling is revealed based on machining kinematics, the instantaneous undeformed cutting thickness is determined, and the milling force mathematical model of indexable face milling cutter considering tool runout is established. Next, the milling force coefficient identification method is analyzed based on the oblique angle cutting theory, and the orthogonal cutting experiment is carried out to determine the milling force coefficient. Finally, the accuracy of the model is verified by milling ZG32MnMo, and the influence of tool runout on cutting forces are analyzed by numerical simulation. The results show that the mean values of prediction errors of the theoretical model considering tool runout compared to the experimental values for the minimum, maximum, magnitude and average values of milling force are 7.0%, 7.3%, 8.3%, 7.0%, respectively, which is a reduction of 46.4%, 13.0%, 36.4%, and 13.2%, respectively, in comparison with the conventional milling force model. The milling force model considering tool runout provides an important reference for realizing tool wear and improving machining state stability.

Key words: milling, tool runout, milling force, kinematics, oblique cutting

CLC Number:

TH161

LIU Dewei, LI Changhe, QIN Aiguo, LIU Bo, CHEN Yun, ZHANG Yanbin. Kinematic Analysis and Milling Force Model for Disc Milling Cutter of Indexable Inserts Considering Tool Runout[J]. Journal of Mechanical Engineering, 2024, 60(21): 365-377.

References

[1] MUTHUSWAMY P. Investigation on sustainable machining characteristics of tools with serrated cutting edges in face milling of AISI 304 stainless steel[J]. Procedia CIRP，2022，105：865-871.
[2] RAHMAN A M，ROB S A，SRIVASTAVA A K. Modeling and optimization of process parameters in face milling of Ti6Al4V alloy using Taguchi and grey relational analysis[J]. Procedia Manufacturing，2021，53：204-212.
[3] 李昊罡，王晓铭，张泽晨，等. 大型风电传动齿轮成形铣削刀具刃形曲线设计[J]. 制造技术与机床，2023(2)：57-65. LI Haogang，WANG Xiaoming，ZHANG Zechen，et al. Curved edge design of forming milling tool for large wind power transmission gear[J]. Manufacturing Technology & Machine Tool，2023(2)：57-65.
[4] PERARD T，VALIORGUE F，MEHMET C，et al. Experimental investigation on surface integrity in a face milling operation[J]. Procedia CIRP，2022，108：400-405.
[5] BEKTAŞ B S，SAMTAŞ G. Optimisation of cutting parameters in face milling of cryogenic treated 6061 aluminium alloy and effects on surface roughness，wear，and cutting temperatures[J]. Surface Topography：Metrology and Properties，2022，10(2)：025013.
[6] 施壮，郭树明，刘红军，等. 生物润滑剂微量润滑磨削GH4169镍基合金性能实验评价[J]. 表面技术，2021，50(12)：71-84. SHI Zhuang，GUO Shuming，LIU Hongjun，et al. Experimental evaluation of minimum quantity lubrication of biological lubricant on grinding properties of GH4169 Nickel-base alloy[J]. Surface Technology，2021，50(12)：71-84.
[7] 王晓铭，张建超，王绪平，等. 冷风微量润滑纳米粒子体积分数对钛合金磨削性能的影响[J]. 金刚石与磨料磨具工程，2020，40(5)：23-29. WANG Xiaoming，ZHANG Jianchao，WANG Xuping，et al. Effect of nanoparticle volume on grinding performance of titanium alloy in cryogenic air minimum quantity lubrication[J]. Diamond & Abrasives Engineering，2020，40(5)：23-29.
[8] 许文昊，李长河，张彦彬，等. 静电雾化微量润滑研究进展与应用[J]. 机械工程学报，2023，59(9)：110-138. XU Wenhao，LI Changhe，ZHANG Yanbin，et al. Research progress and application of electrostatic atomization minimum quantity lubrication[J]. Journal of Mechanical Engineering，2023，59(9)：110-138.
[9] 高腾，李长河，张彦彬，等. 纳米增强生物润滑剂CFRP材料去除力学行为与磨削力预测模型[J]. 机械工程学报，2023，59(13)：325-342. GAO Teng，LI Changhe，ZHANG Yanbin，et al. Mechanical behavior of material removal and predictive force model for CFRP grinding using nano reinforced biological lubricant[J]. Journal of Mechanical Engineering，2023，59(13)：325-342.
[10] DAS L，NAYAK R，SAXENA K K，et al. Determination of optimum machining parameters for face milling process of Ti6A14V metal matrix composite[J]. Materials (Basel)，2022，15(14)：4765.
[11] KUNDRáK J，PáLMAI Z，KARPUSCHEWSKI B，et al. Force and temperature conditions of face milling with varying chip quotient as a function of angle of rotation[J]. Manufacturing Technology，2021，21(2)：214-222.
[12] SCHMITZ T L，COUEY J，MARSH E，et al. Runout effects in milling：Surface finish，surface location error，and stability[J]. International Journal of Machine Tools and Manufacture，2007，47(5)：841-851.
[13] 聂强，黄凯，毕庆贞，等. 微铣削中考虑刀具跳动的瞬时切厚解析计算方法[J]. 机械工程学报，2016，52(3)：169-178. NIE Qiang，HUANG Kai，BI Qingzhen，et al. New mathematic method of calculating instantaneous un-deformed chip thickness with tool run-out in micro-end-milling[J]. Journal of Mechanical Engineering，2016，52(3)：169-178.
[14] 朱锟鹏，李刚. 基于刀具磨损映射关系的微细铣削力理论建模与试验研究[J]. 机械工程学报，2021，57(19)：246-259. ZHU Kunpeng，LI Gang. Theoretical modeling and experimental study of micro milling force based on tool wear mapping[J]. Journal of Mechanical Engineering，2021，57(19)：246-259.
[15] ZHANG X T，LI C H，ZHOU Z M，et al. Vegetable oil-based nanolubricants in machining：From physicochemical properties to application[J]. Chinese Journal of Mechanical Engineering，2023，36(1)：76.
[16] CUI X，LI C H，ZHANG Y B，et al. Comparative assessment of force，temperature，and wheel wear in sustainable grinding aerospace alloy using biolubricant[J]. Frontiers of Mechanical Engineering，2022，18(1)：3.
[17] CUI X，LI C，DING W，et al. Minimum quantity lubrication machining of aeronautical materials using carbon group nanolubricant：From mechanisms to application[J]. Chinese Journal of Aeronautics，2022，35(11)：85-112.
[18] LAI K X，CAO H J，LI H C，et al. Coupling evaluation for material removal and thermal control on precision milling machine tools[J]. Frontiers of Mechanical Engineering，2022，17(1)：12.
[19] MUTHUSWAMY P，NAGARAJAN S K. Experimental investigation on the effect of different micro-geometries on cutting edge and wiper edge on surface roughness and forces in face milling[J]. Lubricants，2021，9(10)：102.
[20] BODZÂS S. Manufacturing analysis of face milling technology by tool setting using the same initial parameters[J]. Strojnícky časopis - Journal of Mechanical Engineering，2023，73(1)：13-24.
[21] DUAN Z，LI C，DING W，et al. Milling force model for aviation aluminum alloy：Academic insight and perspective analysis[J]. Chinese Journal of Mechanical Engineering，2021，34(1)：1-35.
[22] MEHTA S，SINGH G，SAINI A，et al. Finite element analysis of face milling of Ti-6Al-4V alloy considering cutting forces and cutting temperatures[J]. Materials Today：Proceedings，2022，50：2315-2320.
[23] DUAN Z J，LI C H，ZHANG Y B，et al. Mechanical behavior and Semiempirical force model of aerospace aluminum alloy milling using nano biological lubricant[J]. Frontiers of Mechanical Engineering，2023，18(1)：4.
[24] PATEL K M，JOSHI S S. Mechanics of machining of face-milling operation performed using a self-propelled round insert milling cutter[J]. Journal of Materials Processing Technology，2006，171(1)：68-76.
[25] BIRó I，CZAMPA M，SZALAY T. Experimental model for the main cutting force in face milling of a high strength structural steel[J]. Periodica Polytechnica Mechanical Engineering，2015，59(1)：16-22.
[26] CAI S，YAO B，FENG W，et al. An improved cutting force prediction model in the milling process with a multi-blade face milling cutter based on FEM and NURBS[J]. The International Journal of Advanced Manufacturing Technology，2019，104(5-8)：2487-2499.
[27] LIU S，JIN S. Predicting milling force variation in time and space domain for multi-toothed face milling[J]. The International Journal of Advanced Manufacturing Technology，2020，108(7-8)：2269-2283.
[28] GHORBANI H，MOETAKEF-IMANI B. Specific cutting force and cutting condition interaction modeling for round insert face milling operation[J]. The International Journal of Advanced Manufacturing Technology，2016，84：1705-1715.
[29] WOJCIECHOWSKI S，KRAJEWSKA-ŚPIEWAK J，MARUDA R W，et al. Study on ploughing phenomena in tool flank face – workpiece interface including tool wear effect during ball-end milling[J]. Tribology International，2023，181：108313.
[30] ZHOU T，CUI H，WANG Y，et al. Multi-physics analytical modeling of the primary shear zone and milling force prediction[J]. Journal of Materials Processing Technology，2023，316：117949.
[31] LIU D，LIU Z，ZHAO J，et al. Tool wear monitoring through online measured cutting force and cutting temperature during face milling Inconel 718[J]. The International Journal of Advanced Manufacturing Technology，2022，122(2)：729-740.
[32] PLODZIEN M，ZYLKA L，STOIC A. Modelling of the face-milling process by toroidal cutter[J]. Materials (Basel)，2023，16(7)：2829.
[33] LIU D W，LI C H，DONG L，et al. Kinematics and improved surface roughness model in milling[J]. International Journal of Advanced Manufacturing Technology，2022.
[34] LI B，LU Z，JIN X，et al. Tool wear prediction in milling CFRP with different fiber orientations based on multi-channel 1DCNN-LSTM[J]. Journal of Intelligent Manufacturing，2023.
[35] FU H J，DEVOR R，KAPOOR S G. A mechanistic model for the prediction of the force system in face milling operations[J]. Journal of Manufacturing Science and Engineering，1984，106(1)：81-88.
[36] ARMAREGO E J A，WANG J，DESHPANDE N P. Computer-aided predictive cutting model for forces in face milling allowing for tooth run-out[J]. CIRP Annals，1995，44(1)：43-48.
[37] ZHENG H，LI X，WONG Y，et al. Theoretical modelling and simulation of cutting forces in face milling with cutter runout[J]. International Journal of Machine Tools and Manufacture，1999，39(12)：2003-2018.
[38] ANDERSSON C，ANDERSSON M，STÅHL J E. Experimental studies of cutting force variation in face milling[J]. International Journal of Machine Tools and Manufacture，2011，51(1)：67-76.
[39] XIAN C，SHI Y，LUO J，et al. Milling force modeling for disc milling cutter of indexable three-sided inserts considering tool runout[J]. The International Journal of Advanced Manufacturing Technology，2021，115(7-8)：2191-2204.
[40] ZHANG X，GAO Y，GUO Z，et al. Physical model-based tool wear and breakage monitoring in milling process[J]. Mechanical Systems and Signal Processing，2023，184：109641.
[41] BAI X，JIANG J，LI C，et al. Tribological performance of different concentrations of Al₂O₃ nanofluids on minimum quantity lubrication milling[J]. Chinese Journal of Mechanical Engineering，2023，36(1)：1-12.
[42] CHEN T，LIU J，LIU G，et al. Experimental study on titanium alloy cutting property and wear mechanism with circular-arc milling cutters[J]. Chinese Journal of Mechanical Engineering，2023，36(1)：57.
[43] 史兰宇，王晨光，陈杰，等. 高温合金蜂窝芯高速铣削材料去除机理与损伤行为[J]. 机械工程学报，2022，58(23)：284-295. SHI Lanyu，WANG Chenguang，CHEN Jie，et al. Material removal mechanism and damage behavior in high-speed milling of high-temperature alloy honeycomb core[J]. Journal of Mechanical Engineering，2022，58(23)：284-295.
[44] DING H，ZOU B，YANG J，et al. Instantaneous milling force prediction and valuation of end milling based on friction angle in orthogonal cutting[J]. The International Journal of Advanced Manufacturing Technology，2021，116(3-4)：1341-1355.
[45] MERCHANT M E. Basic mechanics of the metal-cutting process[J]. Journal of Applied Mechanics，1944，11(3)：168-175.
[46] ARMAREGO E J A，BROWN R H. The machining of metals[J]. New Jersey：Prentice-Hall，1969.