Milling Simulation

Metal Milling Mechanics, Dynamics and Clamping Principles

Weihong Zhang, Min Wan

• Publisher: Wiley-ISTE
• Year: 2016
• Print ISBN:
  9781786300157
• Edition: 1
• eBook ISBN:
  9781119262916
• Topic: Mathematics
• Subtopic: Applied Mathematics
• Index: Mathematics

Reliable scheduling in cutting conditions is very important in machining processes, and this requires thorough understanding of the physical behaviors of the machining process, which cannot be achieved without understanding the underlying mechanism of the processes. The book describes the mechanics and dynamics together with the clamping principles in milling processes, and can be used as a guideline for graduate students and research engineers who wish to be effective manufacture engineers and researchers.

Many books have focused on common principles, which are suitable for general machining processes, e.g., milling, turning and drilling, etc. This book specifically aims at exploring the mechanics and dynamics of milling processes. Original theoretical derivations and new observations on static cutting force models, dynamic stability models and clamping principles associated with milling processes are classified and detailed. The book is indented as a text for graduate students and machining engineers who wish to intensively learn milling mechanism and machine tool vibration.

1
Cutting Forces in Milling Processes

1.1. Formulations of cutting forces

Milling is a cutting operation which is generally used to remove materials from the blank for the purpose of achieving parts with the desired shape and surface quality. Cutting mechanics of the milling process includes the shearing effect between the cutting edge and the workpiece, the friction effect between the rake face and chip, as well as the ploughing effect between the clearance surface and the machined surface. The combined influence of the three effects lead to the generation of cutting forces, which can result in cutting deflections and can further damage the surface quality of the machined parts. Study of the mechanics of the milling process is of great significance to control surface errors and to plan stable cutting strategy. Milling is a typical multipoint tool operation, whose cutting mechanism involves elastic-plastic mechanics and thermal dynamics. Specific analyses for a detailed understanding of the behavior of temperature and strain rate fields are not covered in this text. In this chapter, we will discuss the generation mechanism of cutting forces, and then detail a series of methods for calibrating the cutting force coefficients which enable us to accurately predict cutting forces.

1.1.1. Mechanics of orthogonal cutting

Orthogonal cutting is usually used to explain the mechanism of material removal, and the three-dimensional oblique cutting process can be evaluated by geometrical and kinematic transformation models, as reported by Altintas [ALT 12]. Without the loss of generality, the orthogonal cutting process is adopted to formulate the cutting forces. Figure 1.1 shows the relationship of cutting forces in the cross-sectional view of an orthogonal cutting pr...

Table of contents

• Cover
• Table of Contents
• Title
• Copyright
• Preface
• Introduction
• 1 Cutting Forces in Milling Processes
• 2 Surface Accuracy in Milling Processes
• 3 Dynamics of Milling Processes
• 4 Mathematical Modeling of the Workpiece-Fixture System
• Bibliography
• Index
• End User License Agreement