Modelling and Analysis of Cutting Forces and Power Consumption Considering Chip Geometry in Milling of AISI D2 Steel

Abstract

Milling is a high performance and high-quality manufacturing activity that has a great potential in the automotive and aerospace sectors. Chip geometry is thought to play an important impact on machining processes, according to the literature. In comparison to conventional drilling, orbital milling is a hole enlarging method that produces holes of superior quality and efficiency. Since cutting forces have a direct impact on power consumption, it is essential to calculate the magnitude of cutter/tool vibration amplitude and cutting forces (x, y and z) in accordance to chip geometry. The objective of this research is to establish an intelligent manufacturing system that can monitor cutting forces while maintaining tool vibration within allowable levels. newlineIn order to forecast cutting forces, power consumption and amplitude of cutter vibration relating to chip geometry, mechanistic models and finite element method (FEM) models have been developed. The current research also intends to promote a simple and less time consuming system for predicting cutting forces, power consumption and tool vibration. Experimental runs were performed on steel (AISI D2) at diverse spindle rotation speeds, orbital speeds and axial depth of cuts using mill cutters with diameters of 8 and 10 mm on DMC-75V linear tri-axes CNC vertical machining center to measure cutting force values and vibration on tool. Cutting force coefficients were empirically estimated using the experimental cutting force values and estimated forces, power consumption related to the chip geometry using mechanistic models. The FEM also used for predicting the cutting forces related to chip geometry. The average error between the results of two methodologies were 4.83%, 4.24%, 4.93%, 4.85%, 5.04% and 3.41% for chip depth, thickness of chip, cutting force and power consumption respectively for helical milling. As per ISO 10816, the experimental results of cutter vibration amplitude were below 20 µm. Using FEM simulation cutter vibration were also predicted;