Improved method for calculating the cutting force of end milling with helical tools

DOU Wei1, YUAN Sheng-wan2, HE Xiao-cong1

Journal of Vibration and Shock ›› 2018, Vol. 37 ›› Issue (10) : 181-186.

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PDF(1171 KB)
Journal of Vibration and Shock ›› 2018, Vol. 37 ›› Issue (10) : 181-186.

Improved method for calculating the cutting force of end milling with helical tools

  • DOU Wei1, YUAN Sheng-wan2, HE Xiao-cong1
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Abstract

It is necessary to determine the cutting forces at each time step for solving milling process dynamic equations. Usually, the integral of the cutting force of helical tool is approximated as follows: the tool is first divided into element disks, and then the elementary forces on each element disk are calculated as a corresponding straight teeth tool in turn, and finally the total cutting force is approximated by summing up all the elementary forces. This approximation approach was not only is timeconsuming but also causes errors. By variable substitution, the switch function of the cutting zone was eliminated from the cutting force integrand, and the integral limits were replaced by the position angle of the cutting edge entering the cutting zone. Then, the analytical expressions for cutting forces of helical tools were obtained, which simplifies the calculation of the milling force, thus can improve the efficiency of solving the dynamic equations for the belical tool milling. The simulation results show that the computational cost of solving a helical tool milling dynamic equation is equivalent to solving that of a straight teeth tool, and without introducing the tool axial discretization errors.

Key words

helical end mill / milling process / dynamic cutting force / time-domain simulation

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DOU Wei1, YUAN Sheng-wan2, HE Xiao-cong1. Improved method for calculating the cutting force of end milling with helical tools[J]. Journal of Vibration and Shock, 2018, 37(10): 181-186

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