Article
Chemistry, Analytical
Tongshun Liu, Qian Wang, Weisu Wang
Summary: In this study, a nonlinear mechanistic cutting force model considering the comprehensive effect of cutting-edge radius and tool wear on the micro-milling force is constructed for micro-milling tool wear monitoring. A stepwise offline optimization approach is proposed to estimate the multiple parameters of the model. Experiments show that, compared with the linear model, the nonlinear model has significantly improved cutting force prediction accuracy and tool wear monitoring accuracy.
Article
Chemistry, Analytical
Shuaishuai Gao, Xianyin Duan, Kunpeng Zhu, Yu Zhang
Summary: This paper proposes an analytic cutting force model considering tool wear and runout, and verifies its accuracy and effectiveness through a series of milling experiments. The results indicate that tool wear has a significant influence on cutting forces and coefficients, especially on axial cutting force and axial force coefficient.
Article
Engineering, Manufacturing
Janos Kundrak, Bernhard Karpuschewski, Zoltan Palmai, Csaba Felho, Tamas Makkai, Dmytro Borysenko
Summary: This article summarizes the results of a project to study the cutting force during milling, which includes analyzing the technology using FEM simulation and validating it through cutting force measurements. The calculations show the importance of the chip ratio in determining the specific features of the technology, and it is advisable to avoid a chip ratio of ap/fz = 1 from an energy perspective.
CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY
(2021)
Article
Automation & Control Systems
Xi Chen, Zhao Zhang, Qi Wang, Dinghua Zhang, Ming Luo
Summary: This paper proposes a cutting force prediction method that takes into account the influence of the machine tool system and tool wear on milling force, thereby improving the accuracy of the prediction.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Automation & Control Systems
Yicong Du, Qinghua Song, Zhanqiang Liu
Summary: This article investigates the size effect phenomenon and surface topography formation mechanism of micro-end mills in micro milling processes, and presents a comprehensive method to predict micro milling force and surface roughness. Experimental results confirm the accuracy and efficiency of this method.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Electrical & Electronic
Chang Yang, Rong Yu, Shanglei Jiang
Summary: In metal-cutting technology, accurate modeling and prediction of milling forces are important research areas. The mechanical model based on unit-cutting force coefficients is widely used due to its high prediction accuracy. However, the calibration of the cutting force coefficients faces challenges when dealing with peripheral milling with non-full radial depth of cut. To address this, a cyclic calibration method considering elastic deformation is proposed.
Article
Automation & Control Systems
Weijie Wang, Weiwei Zhang, Dingchuan Huang, Wei Wang
Summary: This paper proposes a mechanic model to predict cutting forces in micro end milling process and introduces a novel algorithm of instant uncut chip thickness. It suggests a feasible technique to reduce the influence of tool runout and develops an experimental-based cutting force coefficient identification technique. Experimental testing validates the developed cutting force model, demonstrating its validity in predicting cutting forces accurately.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Automation & Control Systems
Yabo Zhang, Qingshun Bai, Fengrui Zhang, Peng Wang
Summary: This study systematically investigates the characteristics and variations of micro-milling force and specific cutting energy through the analysis of fast Fourier transform spectra, curve shapes, and representative parameters. The quasi-dynamic cutting force is adopted to evaluate the micro-milling force, while the specific cutting energy is calculated using the ratio of quasi-dynamic cutting force and average undeformed chip thickness. The results provide important insights into the micro-milling mechanism from the perspective of cutting force and specific cutting energy.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Mathematics
Minh-Quang Tran, Mahmoud Elsisi, Viet Q. Vu, Fahad Albalawi, Sherif S. M. Ghoneim
Summary: This study aims to develop an accurate dynamic cutting force model for milling process and address the issue of machining instability. By using the equilibrium optimizer approach, the model achieves higher prediction accuracy. Furthermore, it can help investigate cutting stability and prevent chatter phenomenon by selecting optimal cutting parameters.
Article
Green & Sustainable Science & Technology
Changping Li, Xinyi Qiu, Zhen Yu, Shujian Li, Pengnan Li, Qiulin Niu, Rendi Kurniawan, Tae Jo Ko
Summary: The developed grinding method for creating micro-groove textures on cutting tools is environmentally friendly and efficient. The experiments on aluminum alloy and tool steel showed that the cutting force is significantly reduced when using the micro-grooved tools, and they have better wear resistance compared to conventional tools.
INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING-GREEN TECHNOLOGY
(2021)
Article
Engineering, Manufacturing
Guolong Zhao, Jichao Song, Zhiwen Nian, Lianjia Xin, Liang Li, Ning He
Summary: Micro-milling is widely used in processing micro-parts and structures, but the existence of chatter reduces efficiency and surface quality. This study focuses on the influence of tool wear on chatter stability using an improved time-varying stability analysis model. Experimental results validate the accuracy of the modified force model and the stability analysis considering tool wear, providing theoretical and technical guidance for improving chatter stability and developing online monitoring in micro-milling processes.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Automation & Control Systems
Tongshun Liu, Yayun Liu, Kedong Zhang
Summary: In this study, a comprehensive micro-milling force model is derived, considering the effects of tool runout, cutting edge radius, and tool wear on cutting force. Experimental results show that the proposed model is efficient in predicting the nonlinear cutting force in micro-milling.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Automation & Control Systems
Xi Chen, Zhao Zhang, Qi Wang, Dinghua Zhang, Ming Luo
Summary: This paper proposes a data-driven method to predict the cutting force of different machine tools through a small number of tests. The method obtains the cutting force coefficients through orthogonal cutting tests, considers the dynamic properties of the machine tool system, and utilizes a regional adaptive method combined with neural networks for prediction. The accuracy of the method is verified through milling tests on different machine tools.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Automation & Control Systems
Yigang Sun, Shenghui Hou, Baichun Li, Hao Yu, Xiaokun Li, Yong Liu, Zhenpeng He, Fangchao Yan
Summary: To analyze and control the micro milling process, this study proposed a method combining FEM and regression analysis to simulate and analyze the cutting process of cutting edge micro-elements at different axial height positions for micro ball-end milling cutters. By combining curve equations and measurements, an accurate model was established, and multiple sets of cutting edge micro-elements of equal thickness were obtained. Through finite element simulation and regression analysis, the micro milling force prediction was achieved, and experiments showed the correctness and reliability of the numerical simulation and force prediction method.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Electrical & Electronic
Miroslav Janota, Petr Kolar, Jiri Falta, Tomas Kozlok
Summary: This paper presents an in-process identification method of the tangential cutting force coefficient using the spindle power signal. The calibration of the spindle drive system was successfully implemented and the results are consistent with the available literature. The method ensures accurate measurement of the tangential component and improves the accuracy and effectiveness of cutting force modeling.
