An effective thread milling force prediction model considering instantaneous cutting thickness based on the cylindrical
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ORIGINAL ARTICLE
An effective thread milling force prediction model considering instantaneous cutting thickness based on the cylindrical thread milling simplified to side milling process Zihua Hu 1
&
Changjiang Qin 1 & Zhiwei Shi 1 & Yiran Tang 1 & Xudong Zhang 1 & Yeming Zou 1
Received: 21 January 2020 / Accepted: 10 August 2020 / Published online: 22 August 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract An effective thread milling force prediction model considering instantaneous cutting thickness is presented based on the cylindrical thread milling simplified to the side milling process. Firstly, based on the thread milling process simplified to side milling, an effective calculation model of instantaneous cutting thickness and a milling force model of single-layer cutter teeth are established considering the specific geometric profile of the cutting edge, chip groove angle, and tooth profile angle of the threaded milling cutter. Then, according to the time-domain difference of each layer of cutter teeth, a simplified thread milling force prediction model corresponding to the number of layers can be obtained. Finally, comparing the predicted values of the proposed model with the experimental results of cylindrical thread milling forces, the results show that the average prediction accuracy of Fx, Fy, and Fz are 90.75%, 83.56%, and 78.79%, respectively. The established simplified cylindrical thread milling force prediction model is accurate and reliable. Keywords Cylindrical thread . Thread milling cutter . Milling force prediction model . Instantaneous cutting thickness
1 Introduction Threaded parts are common fixed connection and motion conversion parts and are widely used in aerospace, petroleum, civil engineering, electric power, and other fields [1, 2]. The traditional thread processing methods include tapping, turning, threading, grinding, etc., but these traditional processing methods often cannot achieve high processing accuracy, and have low processing efficiency and large cutting force, especially when processing difficult-to-cut materials, cannot achieve the desired processing effect [3]. With the development of CNC technology, thread milling has become an indispensable processing method in thread machining, especially for difficult-tocut materials and large-diameter threads [4]. Compared with the traditional thread processing methods, the efficiency of thread milling is higher, the machining accuracy of thread milling is higher, and the universality is stronger [5, 6]. However, in terms of deformation, vibration stability, and surface quality, there are
* Zihua Hu [email protected] 1
School of Mechanical Engineering, Xiangtan University, Xiangtan, Hunan, People’s Republic of China
still processing defects in the thread milling process, such as the curvature deformation and chatter regeneration caused by the cutting force [7]. Therefore, to further improve the quality of the cylindrical thread milling, it is urgently necessary to study the cylindrical thread milling force
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