0
TECHNICAL PAPERS

An Experimental Study of Cutting Forces in High-Speed End Milling and Implications for Dynamic Force Modeling

[+] Author and Article Information
P. T. Mativenga

Department of Mechanical, Aerospace and Manufacturing Engineering, University of Manchester Institute of Science and Technology, Manchester, M60 1QD, UKe-mail: P.Mativenga@umist.ac.uk

K. K. B. Hon

Department of Engineering, The University of Liverpool, Liverpool, L69 3GL, UK

J. Manuf. Sci. Eng 127(2), 251-261 (Apr 25, 2005) (11 pages) doi:10.1115/1.1863254 History: Received July 01, 2003; Revised September 29, 2004; Online April 25, 2005
Copyright © 2005 by ASME
Your Session has timed out. Please sign back in to continue.

References

Salomon, C., 1931, “Verfahren zur Bearbeitung von Metallen Oder bei Einer Bearbeingitung Durch Schneidende Werkzeuge Sich Ahnlich Verhalteden Werkstoffen (Process for the Machining of Metals or Similarly Acting Materials When Being Machined by Cutting Tools),” German Patent No. 523594.
McGee,  F. J., 1979, “High Speed Machining Study: Methods for Aluminum Work-Pieces,” Am. Machinist, 12, March.
El-Wardany,  T. I., Mohammed,  E., and Elbestawi,  M. A., 1996, “Cutting Temperatures of Ceramic Tools in High Speed Machining of Difficult-to-Cut Materials,” Int. J. Mach. Tools Manuf., 36(5), pp. 611–634.
Dewes,  R. C., Ng,  E., Chua,  K. S., Newton,  P. G., and Aspinwall,  D. K., 1997, “Temperature Measurement When High Speed Machining (HSM) Hardened Mould and Die Steel,” Adv. Mater. Process. Technol., 2, pp. 514–521.
Machinability Data Center, 1980, Machining Data Handbook, Vols. 1 and 2, 3rd Development, Metcut Research Associates.
Schulz H., 1996, High-Speed Machining, Carl Hanser Verlag, Munich, pp. 43–45.
Mackinnon, R., Wilson, G. E., and Wilkingson, A. J., 1986, “Tool Condition Monitoring Using Multiple Component Force Measurements,” Proc. International MTDR Conference, Macmillan, London, pp. 317–324.
Fraisa, 2000, “Sphericut 5286 Ball Nose End Mills for High Speed Cutting,” product brochure.
Von Turkovich, B. F., 1979, “Influence of Very High Cutting Speed on Chip Formation Mechanics,” 7th N AMRC, SME Trans. pp. 241–247.
Arndt,  G., 1973, “Ultra High Speed Machining: A Review and Analysis of Cutting Forces,” Proc. London Math. Soc., 187(44/73), pp. 625–634.
Rotberg,  J., Shoval,  S., and Bar,  A., 1997, “Fast Evaluation of Cutting Forces in Milling, Applying no Approximate Models,” Int. J. Adv. Manuf. Technol, 13, pp. 17–26.
Benmohammed, B., Lapuloulade, F., and Moisan, A., 2000, “Determination of the Dynamic Cutting Force Coefficients During Orthogonal Cutting,” 16th National Conference in Manufacturing Research-Advances in Manufacturing Technology, pp, 303–307.
Bao,  W. Y., and Tansel,  I. N., 2000, “Modeling Micro-End-Milling Operations. Part II: Tool Run-Out,” Int. J. Mach. Tools Manuf., 40, pp. 2175–2192.
Fuh,  K. H., and Hwang,  R. M., 1997, “A Predicted Milling Force Model for High Speed End Milling Operation,” Int. J. Mach. Tools Manuf., 37(7), pp. 969–979.
Lee,  L. C., Lee,  K. S., and Gan,  C. S., 1989, “On the Correlation Between Dynamic Cutting Force and Tool Wear,” Int. J. Mach. Tools Manuf., 29, Part 3, pp. 295–303.
Teo,  S. C., Lee,  K. S., and Lee,  L. C., 1993, “A Study of the Consistency of Tool Wear Characteristics and the Criteria for the Onset of Tool Failure,” J. Mater. Process. Technol., 37, pp. 629–637.
Elbestawi,  M. A., Papazafiriou,  T. A., and Du,  R. X., 1991, “In-Process Monitoring of Tool Wear in Milling Using Cutting Force Signature,” Int. J. Mach. Tools Manuf., 31(1), pp. 55–73.
Sarhan,  A., Sayed,  R., Nassr,  A. A., and El-Zahry,  R. M., 2001, “Interrelationships Between Cutting Force Variation and Tool Wear in End Milling,” J. Mater. Process. Technol., 109, pp. 229–235.
Toh,  C. K., 2004, “Static and Dynamic Cutting Force Analysis When High Speed Rough Milling Hardened Steel,” Mater. Des., 25, pp. 41–50.
Mativenga,  P. T., and Hon,  K. K. B., 2003, “A Study of Cutting Forces and Surface Finish in High-Speed Machining of AISI H13 Tool Using Carbide Tools With TiAlN Based Coatings,” Proc. Inst. Mech. Eng., Part B: J. Eng. Manuf., 217, pp. 143–151.
Clancy,  B. E., and Shin,  Y. C., 2002, “A Comprehensive Chatter Prediction Model for Face Turning Operation Including Tool Wear Effect,” Int. J. Mach. Tools Manuf., 42(9), pp. 1035–1044.
Wang,  J. J., and Zheng,  C. M., 2002, “Identification of Shearing and Ploughing Cutting Constants From Average Forces in Ball-End Milling,” Int. J. Mach. Tools Manuf., 42, pp. 695–705.
Schulz, H., 1996, High-Speed Machining, Carl Hanser Verlag, Munich, pp. 19–27.
Komanduri,  R., and Von Turkovich,  B. F., 1981, “New Observations on the Mechanism of Chip Formation When Machining Titanium Alloys,” Wear, 69, pp. 179–188.
Komanduri,  R., 1982, “Some Clarification on the Mechanics of Chip Formation When Machining Titanium Alloys,” Wear, 76, pp. 15–34.
Barry,  J., Bryne,  G., and Lenon,  D., 2001, “Observations on Chip Formation and Acoustic Emission in Machining Ti-6Al-4V Alloy,” Int. J. Mach. Tools Manuf., 41, pp. 1055–1070.
Klocke, F., and Hoppe, S., 2001, “Mechanisms of Chip Formation in High Speed Cutting,” Scientific Fundamentals of HSC, H. Schulz, ed., Carl Hanser Verlag, Munich, pp. 1–10.
Poulachon, G., and Moisan, A., 2001, “A Study of Chip Formation Mechanisms in High Speed Cutting of Hardened Steel,” Scientific Fundamentals of HSC, H. Schulz, ed., Carl Hanser Verlag, Munich, pp. 11–21.
Kruzhanov, V., and Zitz, V., 2001, “Investigation of Chip Formation During High Speed Drilling,” Scientific Fundamentals of HSC, H. Schulz, ed. Carl Hanser Verlag, Munich, pp. 22–31.
Blumke, R., Sahm, A., and Muller, C., 2001, “Influence of Heat-Treatment and Chip Formation in High Speed Machining,” Scientific Fundamentals of HSC, H. Schulz, ed., Carl Hanser Verlag, Munich, pp. 43–52.
Thomson, W. T., and Dahlen, M. D., 1998, The Theory of Vibrations With Applications, 5th Edition, Prentice Hall, Englewood Cliffs, NJ, pp. 479–480.
Kronenberg, M., 1996, Machining Science and Application. Theory and Practice for Operation and Development of Machining Processes, 1st English Edition, Pergamon, New York, p. 11.
DeVries, W. R., 1992, Analysis of Material Removal Processes, Springer-Verlag, Berlin, 1992 pp. 135–136.
Smith,  S., and Tlusty,  J., 1991, “An Overview of Modeling and Simulation of the Milling Process,” ASME J. Eng. Ind., 113, pp. 169–175.
Sohner, J., 2001, “Simulation of the High Speed Milling Process,” Scientific Fundamentals of HSC, H. Schulz, ed., Carl Hanser Verlag, Munich, pp. 66–76.
James, G., 1993, Advanced Modern Engineering Mathematics, Addison-Wesley, Reading, MA, pp. 342–342.

Figures

Grahic Jump Location
Influence of feed on chip serration 28
Grahic Jump Location
Influence of chip load on serration spacing 29
Grahic Jump Location
Theoretical model for chip segmentation in end milling
Grahic Jump Location
Tool workpiece axis configuration for the HSM experiment
Grahic Jump Location
Fx for ball-nose end milling at 3750 rpm
Grahic Jump Location
Fx for ball-nose end milling at 31,500 rpm
Grahic Jump Location
Fy for ball-nose end milling at 3750 rpm
Grahic Jump Location
Fy for ball-nose end milling at 31,500 rpm
Grahic Jump Location
Fz for ball-nose end milling at 3750 rpm
Grahic Jump Location
Fz for ball-nose end milling at 31,500 rpm
Grahic Jump Location
Frequency and magnitude plots of Fx at 3750 rpm
Grahic Jump Location
Frequency and magnitude plots of Fx at 31,500 rpm
Grahic Jump Location
Frequency and magnitude plots of Fy at 3750 rpm
Grahic Jump Location
Frequency and magnitude plots of Fy at 31,500 rpm
Grahic Jump Location
Frequency and magnitude plots of Fz at 3750 rpm
Grahic Jump Location
Frequency and magnitude plots of Fz at 31,500 rpm
Grahic Jump Location
Sources of peak force in HSM of AISI H13 using 6 mm dia tool
Grahic Jump Location
Sources of peak force in HSC of AISI H13 using 12 mm dia tool
Grahic Jump Location
Dynamic performance of force system
Grahic Jump Location
Simulated and experimental FY feed force signals for 10,000 rpm
Grahic Jump Location
Simulated and experimental FY feed force signals for 20,000 rpm

Tables

Errata

Discussions

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In