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Experiment and Modeling of Milling Force Based on Tool Edge Preparation

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Abstract

By altering the cutting edge profile, edge preparation can increase the stability of the cutting process, extend the tool life, and improve the machined surface quality. Herein, a theoretical model of cutting force based on milling tool edge preparation is established according to metal cutting theory and material constitutive equations. The influence of edge radius, milling speed, tool feed, cutting depth, and rake angle on the cutting force are investigated. The results of simulations of the tool milling force of a cemented carbide tool milling 45 steel were performed in the metal cutting modeling software AdvantEdge. Theoretical values of cutting force and torque are compared corresponding values obtained through the milling simulations and cutting experiments, respectively, to verify the proposed cutting force model based on edge preparation. The research results provide the basis for realizing the tool edge preparation effect, the high speed and the high efficiency cutting.

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Abbreviations

F s :

Shear force

F C :

Cutting force in the tool feed direction

F P :

Axial cutting force

h :

Cutting thickness

a e :

Radial cutting depth

a p :

Cutting depth

δ :

Spiral angle

f z :

Feed engagement

φ :

Cut-out angle

ω :

Cutting angle

d :

Milling tool diameter

γ 0 :

Rake angle

β :

Friction angle of the rake face

ϕ :

Shear angle

V :

Cutting speed

b :

Contact length between the tool and the chip

τ :

Material flow stress in the shear zone

ρ :

Angle between the chip and the uncut layer

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Funding

This work is supported by the National Natural Science Foundation of China.(Research on the influence of tool passivation and asymmetric cutting edge on cutting performance),China.

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    Authors and Affiliations

    1. Mechanical Engineering College, Guizhou University, Jiaxiu South Road, Huaxi District, Guiyang, 550025, Guizhou, China

      XF. Zhao, Y. Yang, L. He & ZG. Feng

    2. Mechanical Engineering College, Liupanshui Normal University, No. 19, Yucai lane, Minghu Road, Zhongshan District, Liupanshui, 553004, Guizhou, China

      L. He

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    1. XF. Zhao
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    Contributions

    Xuefeng ZHAO: Graduate tutors, put forward research topics; Design the research plan; Obtaining research funding;

    Yong YANG:Master’s degree student and Research and organize literature; Design the framework of the thesis; Draft papers; Revise the thesis;

    Lin He: Supervisor of the master degree dissertation;

    Zhiguo Feng: Supervisor of the master degree dissertation.

    Corresponding author

    Correspondence to XF. Zhao.

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    Yong Yang, Lin He and Zhiguo Feng contributed equally to this work.

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    Cite this article

    Zhao, X., Yang, Y., He, L. et al. Experiment and Modeling of Milling Force Based on Tool Edge Preparation. Exp Tech 46, 761–773 (2022). https://doi.org/10.1007/s40799-021-00517-6

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    • DOI: https://doi.org/10.1007/s40799-021-00517-6

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