Operational Cutting Force Identification in End Milling Using Inverse Technique to Predict the Fatigue Tool Life
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RESEARCH PAPER
Operational Cutting Force Identification in End Milling Using Inverse Technique to Predict the Fatigue Tool Life Ratan A. Patil1 · Shrinivas L. Gombi2 Received: 12 June 2020 / Accepted: 19 August 2020 © Shiraz University 2020
Abstract The assessment of actual cutting forces is vital and essential task for the design and analysis of structural systems. The present study deals with experimental investigation of cutting forces during machining, considering the initial impact during the engagement of cutting tool and work piece. The cutting forces are studied on HSS tool and carbon steel work piece for various cutting parameters. Cutting force assessment directly during machining is a complex task, while the responses because of these forces can be measured using a sensor. The impact cutting force identification on end mill tool is investigated using inverse technique with the aid of frequency response function which measures the structural responses. Experimentally predicted cutting forces are compared with analytically determined cutting forces. Finite element analysis of end mill tool is conceded subjected to the cutting forces to estimate the induced stress, and using induced stress the fatigue life of end mill tool is predicted. The results show that experimental cutting forces predicted are in close agreement with the analytically determined cutting forces. The significance level of the experimental method is 99% having 1% error. Impact effect of cutting forces observed is in the range of 1.093–1.409 than the average cutting force. Cutting tools designed using average cutting force provides false picture of tool life and must be predicted using actual cutting forces. Keywords Impact force · Inverse problem · Frequency response function · Force identification
1 Introduction In the world of competition, industries make use of maximum possible out of the resources available. The life or the span of the cutting tool is greatly influenced by the machining cutting forces since these forces transmitted to the cutting tool are non-static. During the first machining cut the cutting tool experiences larger magnitude of impact cutting forces which is the key factor in the design of cutting tool. Cutting parameters like depth of cut, feed rate, and speed have an effect on the cutting forces. The untimely failure of tool is the crucial threat in conventional manufacturing plants today since the design of tools is based on average cutting forces. Prolonged service lives of materials is the desire of today’s engineers, and shaping the materials into finished products requires processes that are able to maintain * Ratan A. Patil [email protected] 1
Jain College of Engineering, Belgaum, India
KLS’ Gogte Institute of Technology, Belgaum, India
2
tight geometric tolerances and improved surface finish. The life of a cutting tool can be determined by a number of means like unexpected tool failure and gradual wearing of certain regions of the face and flank of the cutting tool. The cutting tool life is me
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