Trochoidal milling: investigation of a new approach on uncut chip thickness modeling and cutting force simulation in an alternative path planning strategy
Trochoidal milling: investigation of a new approach on uncut chip thickness modeling and cutting force simulation in an alternative path planning strategy
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DOI：
10.1007/s00170-018-1967-0
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发表时间：
2018-04
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影响因子：
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通讯作者：
Farbod Akhavan Niaki;Abram Pleta;L. Mears
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文献类型：
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作者：
Farbod Akhavan Niaki;Abram Pleta;L. Mears
摆线铣削是一种可选的刀具路径策略，已被证明可以提高生产率，延长刀具寿命，并减少合力。虽然以前报道了摆线铣削相对于传统的槽式或肩式铣削的优点，但由于摆线刀具轨迹的复杂性，使得建立一个解析力模型变得非常复杂。根据刀具轨迹曲线的自交点和交点的几何关系，提出了一种建立摆线铣削未切屑厚度模型的数值算法。此外，还在槽切和摆线铣削加工中进行了大量的实验，以研究切削压力系数与刀具轨迹参数的关系，并建立了两者之间的关系模型。此外，对所建立的切屑厚度和切削力系数模型在预测切削力方面的性能进行了评估，结果表明，该模型预测进给方向和所有试验台之间的最大切削力的总平均误差为8%，而预测横向最大切削力的总平均误差为17%。这证明了所提出的方法在离线模拟切削力方面的潜力，这是选择合适的刀具和工艺参数以提高切割生产率的关键步骤。
Trochoidal milling is an alternative tool path strategy which has been shown to increase productivity, improve tooling life, and reduce resultant cutting forces. While the advantages of trochoidal milling over conventional slot or shoulder milling were previously reported, the complexity of trochoid tool path makes developing an analytical force model highly complicated. In this work, a numerical algorithm to construct the uncut chip thickness model in trochoidal milling is introduced, which is based on the geometrical relation of self-intersection and cross-intersection points of the tool path curve. In addition, an extensive series of experiments is carried out in slot and trochoidal-milling operations in order to investigate the dependency of cutting pressure coefficients on tool path parameters and to develop a model to relate the two. Furthermore, the performance of the developed model for uncut chip thickness and the cutting pressure coefficients are evaluated in predicting cutting forces; it is shown that the model predicts the maximum cutting force in the feed direction and between all the testing sets with 8% total average error, while 17% total average error is observed in predicting maximum cutting force in the lateral direction. This demonstrates the potential of the proposed approach in offline simulation of the cutting forces which is a critical step in selecting proper tooling and process parameters to increase productivity of the cut.