Abstract：For revealing the regularity of cutting force varying in multi-edge milling with flat end mills, the mathematical expressions of nominal cutting forces in horizontal directions were deduced, and these cutting forces were found to be harmonic functions of rotational angle, their constants were in proportion to the numbers of simultaneously cutting edges. With normalizing the coefficients of cutting force expressions, and applying simulation method, the dimensionless means and amplitudes at tooth frequency of nominal cutting forces for flat end mills with common flute were obtained. The simulation results show that: in multi-edge cutting, the means of nominal cutting force in radial depth direction prominently increases, while its amplitudes at tooth frequency either increase or decrease. Experiments of cutting and force measuring for 4-flute flat end mill were done, the results agree with those of mathematically deduction and simulation. Research results imply that, comparing with single-flute continuous cutting, the static cutting force in radial depth direction of multi-edge cutting will prominently increase; in horizontal directions, multi-edge cutting may be more or less stable; the multi-edge cutting with even-flute mills may be especially stable. Research results can be used in milling for selecting immersion angle optimally.
National Natural Science Foundation of China（No. 51375099,51375100）
引用本文:
刘璨;吴敬权;刘焕牢;谭光宇. 平底立铣刀在多刃切削时的切削力变化规律研究[J]. 中国机械工程, 2016, 27(10): 1352-1357.
Liu Can;Wu Jingquan;Liu Huanlao;Tan Guangyu. Study on Variation Regulation of Cutting Forces in Multi-edge Cutting with Flat End Mills. China Mechanical Engineering, 2016, 27(10): 1352-1357.
Bobrenkov O A, Khasawneh F A, Butcher E A, et al. Analysis of Milling Dynamics for Simultaneously Engaged Cutting Teeth[J]. Journal of Sound and Vibration, 2010, 329: 585-606.
[2]
Kim G D, Chu C N. In-process Tool Fracture Monitoring in Face Milling Using Spindle Motor Current and Tool Fracture Index[J]. Int. J. Adv. Manuf. Technol., 2001, 18:383-389.
[3]
Hwang J H, Oh Y T, Kwon W T, et al. In-process Estimation of Radial Immersion Ratio in Face Milling Using Cutting Force[J]. Int. J. Adv. Manuf. Technol., 2003, 22:313-320.
Li Huzeng, Zhang Guohong, Wei Heng. Computer Simulation of Cutting Vibrations in Face Milling with Multiblade Cutter[J]. Journal of Tongji University, 2000, 28(1):55-59.
Salgado M A, López de Lacalle L N, Lamikiz A, et al. Evaluation of the Stiffness Chain on the Deflection of End-mills under Cutting Forces[J]. Int. J. Mach. Tools Manuf., 2005, 45: 727-739.
[7]
Krüger M, Denkena B. Model-based Identification of Tool Runout in End Milling and Estimation of Surface Roughness from Measured Cutting Forces[J]. Int. J. Adv. Manuf. Technol., 2013, 65:1067-1080.
[8]
Sun Yujing, Sun Jie, Li Jianfeng, et al. Modeling of Cutting Force under the Tool Flank Wear Effect in End Milling Ti6Al4V with Solid Carbide Tool[J]. Int. J. Adv. Manuf. Technol., 2013, 69:2545-2553.
Li Binglin, Hu Yujin, Wang Xuelin, et al. Cutting Force Prediction Based on Oblique Cutting Theory in End Milling[J]. China Mechanical Engineering, 2011, 22(19):2283-2288.
[10]
Tlusty J, Macneil P. Dynamics of Cutting Forces in End Milling[J]. Annals of the CIRP, 1975, 24(1):21-25.
Liu Can, Wu Jingquan, Li Guanghui, et al. Identification of Mills Eccentricity Based on Peak Force of Single Edge[J]. Journal of Mechanical Engineering, 2013, 49(1):185-190.
[12]
Janez G, Martin K, Klaus W. Mechanistic Identification of Specific Force Coefficients for a General End Mill[J]. Int. J. Mach. Tools. Manuf., 2004, 44:401-414.
[13]
Engin S, Altintas Y. Mechanics and Dynamics of General Milling Cutters—Part I: Helical End Mills[J]. Int. J. Mach. Tools. Manuf., 2001, 42:2195-2212.
