Prediction of Forces, Torque and Power in Face Milling Operations
The need for reliable quantitative predictions of the forces, torque and power in face milling operations is discussed and the alternative force prediction approaches reviewed and compared. It is shown that the traditional direct experimental or ‘empirica
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E.J.A. Armarego and J, Wang University of Melbourne, Parkville, Victoria, Australia
KEY WORDS: Face Milling, Force Modelling, Milling, Force Prediction. ABSTRACT: The need for reliab.le quantitative predictions of the forces, torque and power in face milling operations is discussed and the alternative force prediction approaches reviewed and compared. It is shown that the traditional direct experimental or 'empirical' approach is expensive, laborious and only considers a few variables and average force components but the curve fitted 'empirical' equations are most suitable for economic optimisation. The semi-empirical 'mechanistic' approach is more comprehensive but does not consider all fluctuating and average force components or provide explicit force equations. By contrast the 'unified mechanics of cutting approach' is the most comprehensive and generic approach allowing for all the forces and most variables but results in complex equations. However extensive simulation studies of this proven approach have enabled comprehensive 'empirical-type' equations to be established without significant loss in predictive capability. These simpler equations which allow for numerous variables are most suitable for machine tool and cutter design purposes and for economic optimisation of these operations. The importance of fundamental cutting analyses in predictive modelling of machining operations is highlighted.
1. INTRODUCTION Machining is one of the oldest process for shaping components and due to its versatility and precision, achieved through continual innovation, research and development, has become an indispensable process used in manufacturing industry. In more recent years machining has led the way towards the 'revolution' in modern computer based manufacturing through developments in computer controlled machining systems and Published in: E. Kuljanic (Ed.) Advanced Manufacturing Systems and Technology, CISM Courses and Lectures No. 372, Springer Verlag, Wien New York, 1996.
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E.J .A. Armarego and J. Wang
flexible automation. These modem automated systems have been forecast to increase the total available production time a component spends being machined from 6% to 10% in conventional (manual) systems to 65% to 80% making machining more important than ever before[l, 2]. As a consequence the long recognised need for improved and reliable quantitative predictions of the various technological performance measures such as the forces, power and tool-life in order to optimise the economic performance of machining operations has also become more pressing than ever before if full economic benefits of the capital intensive modem systems are to be achieved [3]. This pressing need for reliable quantitative performance data has recently been re-emphasised in a CIRP survey [4]. The estimation or prediction of the various technological performance measures represents a formidable task when the wide spectrum of practical machining operations such as turning and milling as well as the numerous process variables such as the to
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