A hybrid approach for cutting force prediction in flank milling based on analytical and 3D finite element method
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ORIGINAL ARTICLE
A hybrid approach for cutting force prediction in flank milling based on analytical and 3D finite element method Junli Li 1 & Xiaojiang Cai 2 & Qinglong An 3 & Ming Chen 3 Received: 26 February 2020 / Accepted: 5 August 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Flank milling is one of the most widely used milling processes characterized by high machining efficiency. However, due to the low thermal conductivity and high-temperature strength of nickel-based superalloy Inconel 718, flank milling of Inconel 718 is still an extremely difficult and challenging task in which the milling cutter suffers large cutting force and excessive tool wear. Therefore, prediction of cutting force in milling process has caused due attention and became a major concern in manufacturing process. The present work is thus aimed at developing a new cutting force model for flank milling, which might try to eliminate the drawbacks of pure analytical force model, data-based reasoning method (DBRM), and full three dimensional (3D) finite elements (FE) model. The hybrid cutting force model is conducted by discretizing cutting edge into fragments based on infinitesimal method and regarding each fragment as a 3D oblique cutting FEM model. With the integration of 3D predicted cutting force along the axis considering the run-in and run-out effect of each cutting edge, the predicted cutting force can be obtained. Finally, the predicted results showed a good agreement with that of experimental. Keywords Flank milling . Cutting force prediction . Hybrid model . Finite difference method . 3D finite element
Abbreviations FE Finite element Faj Cutting force in axial direction Frj Cutting force in radial direction Ftj Cutting force in tangential direction αn Tool normal rake angle ηc Chip-flow angle i Inclination of the main cutting edge fz Feed per tooth (mm/tooth) D Diameter of the milling cutter (mm) h Equivalent undeformed chip height l′ Equivalent undeformed chip length σ Flow stress εpl Equivalent plastic strain * Junli Li [email protected] 1
School of Mechanical Engineering, Shanghai University of Engineering Science, Shanghai 201620, People’s Republic of China
2
Shanghai Aerospace Control Technology Institute, Shanghai 201109, People’s Republic of China
3
School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, People’s Republic of China
ε0 ε pl ε f pl εel εth vc vf αe θj T0 Tm A B C n m τf σn ψ σs T ap d1~d5
Strain rate parameter Equivalent plastic strain rate Equivalent failure plastic strain Elastic strain Strain caused by heat extension Cutting speed Feed rate (mm/min) Tool effective rake angle Position angle of cutter Reference temperature Melting temperature JC material parameters JC material parameters JC material parameters JC material parameters JC material parameters Frictional stress Normal stress Phase difference Shear flow stress Temperature parameter Axis depth of cut Failure parameters
Int J Adv Manuf Technol Fig. 1 Schematic of milling force model
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