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.

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URL: http://www.cjmenet.com.cn/EN/10.3901/JME.2024.21.365

http://www.cjmenet.com.cn/EN/Y2024/V60/I21/365

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