Digital force prediction for milling

Michael Gomez, Timothy No, Tony Schmitz

Research output: Contribution to journalConference articlepeer-review

7 Scopus citations

Abstract

This paper presents a fully digital, integrated approach for milling force prediction with arbitrary end mill-work material combinations. The approach includes: 1) structured light scanning to identify the end mill's cutting edge macro-geometry along the tool axis; 2) structured light scanning to measure the cutting edge cross-sectional rake and relief profiles; 3) finite element analysis of orthogonal cutting to determine the force model coefficients that relate the force to chip area using the work material's constitutive model and tool's rake and relief profiles; and 4) time domain simulation with inputs that include the measured cutting edge macro-geometry, finite element-based force model, and measured structural dynamics. Milling force predictions are compared to in-process measurements to validate the method.

Original languageEnglish
Pages (from-to)873-881
Number of pages9
JournalProcedia Manufacturing
Volume48
DOIs
StatePublished - 2020
Externally publishedYes
Event48th SME North American Manufacturing Research Conference, NAMRC 48 - Cincinnati, United States
Duration: Jun 22 2020Jun 26 2020

Funding

The authors gratefully acnk oledw ge financial support from the National Science Foundation (CMMI -1561221). The authors gratefully acknowledge financial support from the National Science Foundation (CMMI-1561221). Additionally, this research was supported by the DOE Office of Energy Efficiency and Renewable Energy (EERE), Energy and Transportation Science Division and used resources at the Manufacturing Demonstration Facility, a DOE-EERE User Facility at Oak Ridge National Laboratory. Finally, the authors gratefully fully acknowledge support from Third Wave Systems for the use of AdvantEdgeTM in this study. Additionally, t his research aw s supported by the DOE Office of Energy Efficiency and eR neaw ble Energy (EEER ), Energy and Transportation Science Division and used resources at the Manufacturing Demonstration Facility, a DOE -EERE User Facility at Oak idR ge National abL oratory. Finally, the authors gratefully fully acnk oledw ge support from Third Wave Systems for the use of AdvantEdge TM in this study.

Keywords

  • Digital twin
  • Finite element analysis
  • Force
  • Machining
  • Modeling
  • Structured light

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