Mechanistic modelling for predicting cutting forces in machining considering effect of tool nose radius on chip formation and tool wear land
Mechanistic modelling for predicting cutting forces in machining considering effect of tool nose radius on chip formation and tool wear land
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DOI：
10.1016/j.ijmecsci.2018.05.004
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发表时间：
2018-07-01
影响因子：
7.3
通讯作者：
Choudhury, Sounak K.
中科院分区：
文献类型：
--
作者：
Orra, Kashfull;Choudhury, Sounak K.
加工过程中的刀具磨损会导致刀具几何形状的变化，从而对工艺的性能特征产生不利影响。人们提出了各种力模型来补偿刀具磨损，从而提高工艺性能。所进行的研究提出了一种机械模型来预测基于三维切削操作的切削力。该模型是为了预测由于切屑形成和磨损的切削刀具（包括切削刀尖半径）而产生的力而开发的。由于切屑形成而预测的力是切屑流角和等效切削刃几何形状的函数。由于切削刀具磨损而产生的力的预测是基于实际的切屑刀具接触面积和摩擦力。估计的总力已进一步优化，以获得模型的准确性。优化过程是通过使用与理想解决方案相似的顺序偏好技术来实现的。所提出的力模型的结果已经过实验验证，并且发现与Huang和Liang[39]以及Chinchanikar和Choudhury[21]提出的力模型的结果非常一致。此外，还开发了回归方程，以检查所提出模型的充分性。所提出的建模方法可以很容易地扩展到其他加工操作，例如钻孔和铣削。
Tool wear during machining has been seen to result in changes in tool geometry, which adversely affect the performance characteristic of the process. Various force models have been proposed to compensate for the tool wear and thus enhance the process performance. The study undertaken proposes a mechanistic model to predict the cutting forces based on three-dimensional cutting operations. The model has been developed for predicting forces due to chip formation and due to worn-out cutting tool including cutting tool nose radius. The force that has been predicted due to chip formation is a function of chip flow angle and equivalent cutting edge geometry. The prediction of force due to worn-out cutting tool is based on the actual chip-tool contact area and the rubbing force. The total force estimated has been further optimised to get accuracy in the model. Optimisation process is achieved by using a technique of order preference by similarity to the ideal solution. Results of the proposed force model have been experimentally validated as well as found to be in good agreement with the results of the force models proposed by Huang and Liang [39] and Chinchanikar and Choudhury [21]. Further, a regression equation has been developed in order to check the adequacy of the proposed model. The modelling approach proposed may be readily extended to other machining operations such as drilling and milling.