For a generalized helical end mill, this paper presents a frequency domain force model considering the ploughing as well as the shearing mechanisms. The differential chip load and the corresponding cutting forces are first formulated through differential geometry for a general helical cutting edge. The differential cutting force is assumed to be a linear function of the chip load with a proportional shearing force and a constant ploughing force. The total milling force in the angle domain is subsequently composed through convolution integration and analyzed by Fourier analysis. The frequency domain model has the parameters of a general milling process all integrated in a single framework with their roles clearly defined so that Fourier coefficients of the milling force can be obtained for any analytically definable helical cutter. Applications are illustrated for three common helical cutters: the cylindrical, taper, and ball end mills. Furthermore, as an inverse application, a linear algebraic equation is formulated for the identification of six cutting constants from the average forces of two slot milling tests. Demonstration and verification of the milling force model as well as the identification of cutting constants are carried out through experiments with three types of milling cutters.
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ASME 2002 International Mechanical Engineering Congress and Exposition
November 17–22, 2002
New Orleans, Louisiana, USA
Conference Sponsors:
- Manufacturing Engineering Division
ISBN:
0-7918-3641-X
PROCEEDINGS PAPER
A Frequency Domain Force Model With Shearing and Ploughing Mechanisms for a Generalized Helical End Mill
J.-J. Junz Wang,
J.-J. Junz Wang
National Cheng Kung University, Tainan, Taiwan
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C. M. Zheng
C. M. Zheng
National Cheng Kung University, Tainan, Taiwan
Search for other works by this author on:
J.-J. Junz Wang
National Cheng Kung University, Tainan, Taiwan
C. M. Zheng
National Cheng Kung University, Tainan, Taiwan
Paper No:
IMECE2002-39117, pp. 365-373; 9 pages
Published Online:
June 3, 2008
Citation
Wang, JJ, & Zheng, CM. "A Frequency Domain Force Model With Shearing and Ploughing Mechanisms for a Generalized Helical End Mill." Proceedings of the ASME 2002 International Mechanical Engineering Congress and Exposition. Manufacturing. New Orleans, Louisiana, USA. November 17–22, 2002. pp. 365-373. ASME. https://doi.org/10.1115/IMECE2002-39117
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