<p>To solve the problems of high repeatability and enormous time cost in the calculation process of the analytical prediction model of milling force, this paper establishes an efficient analytical prediction model based on the contact relationship between the tool and the workpiece. Transform this contact relationship into the relationship between the helical line in a two-dimensional plane and the milling area. The reasons for the change of milling force caused by tool geometric parameters ( helix angle, milling cutter radius, cutting edge number) and cutting parameters (depth of cut, width of cut) are analyzed. The expression of the two-dimensional cutting contact relationship is established, and the milling force prediction model without window function is constructed by combining the numerical simulation model, which simplifies the repetitive calculation steps in the calculation process and defines the boundary conditions of the milling area. The established two-dimensional equation of the micro-element cutting force function and the spatial cutting edge line in the milling region is used as the basis of the milling force prediction model, which not only ensures the accuracy of milling force prediction but also improves the calculation efficiency of the model. After the cutting experiments of multiple machining parameters and tool geometric parameters, the prediction results of the model are compared with the experiments, proving the model’s effectiveness. Compared with the existing milling force prediction model, the computational efficiency has been greatly improved.</p>

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An efficient calculation method of milling force

  • Shaocong Sun,
  • Caixu Yue,
  • Xianli Liu,
  • Zhitao Chen,
  • Junhui Lu

摘要

To solve the problems of high repeatability and enormous time cost in the calculation process of the analytical prediction model of milling force, this paper establishes an efficient analytical prediction model based on the contact relationship between the tool and the workpiece. Transform this contact relationship into the relationship between the helical line in a two-dimensional plane and the milling area. The reasons for the change of milling force caused by tool geometric parameters ( helix angle, milling cutter radius, cutting edge number) and cutting parameters (depth of cut, width of cut) are analyzed. The expression of the two-dimensional cutting contact relationship is established, and the milling force prediction model without window function is constructed by combining the numerical simulation model, which simplifies the repetitive calculation steps in the calculation process and defines the boundary conditions of the milling area. The established two-dimensional equation of the micro-element cutting force function and the spatial cutting edge line in the milling region is used as the basis of the milling force prediction model, which not only ensures the accuracy of milling force prediction but also improves the calculation efficiency of the model. After the cutting experiments of multiple machining parameters and tool geometric parameters, the prediction results of the model are compared with the experiments, proving the model’s effectiveness. Compared with the existing milling force prediction model, the computational efficiency has been greatly improved.