New Mathematical Method for the Determination of Cutter Runout Parameters in Flat-end Milling  

作　　者：GUO Qiang SUN Yuwen GUO Dongming ZHANG Chuantai 

机构地区：[1]Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education,Dalian University of Technology,Dalian 116024,China

出　　处：《Chinese Journal of Mechanical Engineering》2012年第5期947-952,共6页中国机械工程学报（英文版）

基　　金：supported by National Natural Science Foundation of China (Grant No. 51075054);National Basic Research Program of China (973 Program, Grant No. 2005CB724100);Program for New Century Excellent Talents in University of China (Grant No. NCET-08-081)

摘　　要：The cutting force prediction is essential to optimize the process parameters of machining such as feed rate optimization, etc. Due to the significant influences of the runout effect on cutting force variation in milling process, it is necessary to incorporate the cutter runout parameters into the prediction model of cutting forces. However, the determination of cutter runout parameters is still a challenge task until now. In this paper, cutting process geometry models, such as uncut chip thickness and pitch angle, are established based on the true trajectory of the cutting edge considering the cutter runout effect. A new algorithm is then presented to compute the cutter runout parameters for flat-end mill utilizing the sampled data of cutting forces and derived process geometry parameters. Further, three-axis and five-axis milling experiments were conducted on a machining centre, and resulting cutting forces were sampled by a three-component dynamometer. After computing the corresponding cutter runout parameters, cutter forces are simulated embracing the cutter runout parameters obtained from the proposed algorithm. The predicted cutting forces show good agreements with the sampled data both in magnitude and shape, which validates the feasibility and effectivity of the proposed new algorithm of determining cutter runout parameters and the new way to accurately predict cutting forces. The proposed method for computing the cutter runout parameters provides the significant references for the cutting force prediction in the cutting process.The cutting force prediction is essential to optimize the process parameters of machining such as feed rate optimization, etc. Due to the significant influences of the runout effect on cutting force variation in milling process, it is necessary to incorporate the cutter runout parameters into the prediction model of cutting forces. However, the determination of cutter runout parameters is still a challenge task until now. In this paper, cutting process geometry models, such as uncut chip thickness and pitch angle, are established based on the true trajectory of the cutting edge considering the cutter runout effect. A new algorithm is then presented to compute the cutter runout parameters for flat-end mill utilizing the sampled data of cutting forces and derived process geometry parameters. Further, three-axis and five-axis milling experiments were conducted on a machining centre, and resulting cutting forces were sampled by a three-component dynamometer. After computing the corresponding cutter runout parameters, cutter forces are simulated embracing the cutter runout parameters obtained from the proposed algorithm. The predicted cutting forces show good agreements with the sampled data both in magnitude and shape, which validates the feasibility and effectivity of the proposed new algorithm of determining cutter runout parameters and the new way to accurately predict cutting forces. The proposed method for computing the cutter runout parameters provides the significant references for the cutting force prediction in the cutting process.

关 键 词：flat end milling cutter runout cutting force five-axis machining 

分 类 号：TG711[金属学及工艺—刀具与模具] TU411.3[建筑科学—岩土工程]