TY - JOUR

T1 - Identification of the specific cutting force for geometrically defined cutting edges and varying cutting conditions

AU - Denkena, Berend

AU - Vehmeyer, Jost

AU - Niederwestberg, Daniel

AU - Maaß, Peter

N1 - Funding Information: The presented results have been obtained within the research project Thermomechanical Deformation of Complex Workpieces in Drilling and Milling Processes ( DE447/90-2 , MA1657/21-2 ) within the DFG Priority Program 1480 Modeling, Simulation and Compensation of Thermal Effects for Complex Machining Processes. The authors would like to thank the DFG for its financial and organizational support of the project. Copyright: Copyright 2020 Elsevier B.V., All rights reserved.

PY - 2014/4/13

Y1 - 2014/4/13

N2 - Cutting force modeling is a major discipline in the research of cutting processes. The exact prediction of cutting forces is crucial for process characterization and optimization. Semi-empirical and mechanistic force models have been established, but the identification of the specific cutting force for a pair of tool and workpiece material is still challenging. Existing approaches are depending on geometrical idealizations and on an extensive calibration process, which make practical and industrial application difficult. For nonstandard tools and five axis kinematics there does not exist a reasonable solution for the identification problem. In this paper a co-operative force model for the identification of the specific cutting forces and prediction of integral forces is presented. The model is coupled bidirectionally with a multi-dexel based material removal model that provides geometrical contact zone information. The nonlinear specific forces are modeled as polynomials of uncut chip thickness. The presented force model is not subjected to principal restrictions on tool shape or kinematics, the specific force and phase shift are identified with help of least square minimization. The benefit of this technique is that no special calibration experiments are needed anymore, which qualifies the method to determine the specific forces simultaneously during the machining process. In this paper, experiments with different cutting conditions are analyzed and systematically rated. Finally, the method is validated by experiments using different cutting conditions.

AB - Cutting force modeling is a major discipline in the research of cutting processes. The exact prediction of cutting forces is crucial for process characterization and optimization. Semi-empirical and mechanistic force models have been established, but the identification of the specific cutting force for a pair of tool and workpiece material is still challenging. Existing approaches are depending on geometrical idealizations and on an extensive calibration process, which make practical and industrial application difficult. For nonstandard tools and five axis kinematics there does not exist a reasonable solution for the identification problem. In this paper a co-operative force model for the identification of the specific cutting forces and prediction of integral forces is presented. The model is coupled bidirectionally with a multi-dexel based material removal model that provides geometrical contact zone information. The nonlinear specific forces are modeled as polynomials of uncut chip thickness. The presented force model is not subjected to principal restrictions on tool shape or kinematics, the specific force and phase shift are identified with help of least square minimization. The benefit of this technique is that no special calibration experiments are needed anymore, which qualifies the method to determine the specific forces simultaneously during the machining process. In this paper, experiments with different cutting conditions are analyzed and systematically rated. Finally, the method is validated by experiments using different cutting conditions.

KW - Determination of undeformed chip thickness

KW - Dexel model

KW - Force prediction

KW - Mechanistic force modeling

KW - Non-standard tools

KW - Specific cutting force

UR - http://www.scopus.com/inward/record.url?scp=84898960012&partnerID=8YFLogxK

U2 - 10.1016/j.ijmachtools.2014.03.009

DO - 10.1016/j.ijmachtools.2014.03.009

M3 - Article

AN - SCOPUS:84898960012

VL - 82-83

SP - 42

EP - 49

JO - International Journal of Machine Tools and Manufacture

JF - International Journal of Machine Tools and Manufacture

SN - 0890-6955

ER -