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A modified analytical cutting force prediction model under the tool flank wear effect in micro-milling nickel-based superalloy

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Abstract

This study attempts to develop a micro-milling force model under cutting conditions considering tool flank wear effect during micro-milling of nickel-based superalloy with coated carbide micro-milling tools based on our three-dimensional dynamic cutting force prediction model established earlier. The tool wear condition in micro-milling nickel-based superalloy was obtained by finite element method. A 3D thermal-mechanical coupled simulation model for micro-milling nickel-based superalloy was developed to obtain the tool wear conditions and the distribution of stress. For the given tool geometries and machining conditions, the cutting forces considering tool flank wear effect could be determined conveniently. In addition, experiments of micro-milling nickel-based superalloy were conducted to estimate the validity of the modified model. The results showed that the proposed modified force analytical model could predict micro-milling cutting forces more accurately.

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Authors and Affiliations

  1. School of Mechanical Engineering, Key Laboratory for Precision and Non-traditional Machining Technology of the Ministry of Education, Dalian University of Technology, 2 Linggong Road, Gangjingzi, Dalian, 116024, China

    Xiaohong Lu, Furui Wang, Zhenyuan Jia, Likun Si & Chi Zhang

  2. The George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Georgia Institute of Technology North Avenue, Atlanta, GA, 30332, China

    Steven Y. Liang

Authors
  1. Xiaohong Lu
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  2. Furui Wang
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  3. Zhenyuan Jia
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  4. Likun Si
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  5. Chi Zhang
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  6. Steven Y. Liang
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Correspondence to Zhenyuan Jia.

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Lu, X., Wang, F., Jia, Z. et al. A modified analytical cutting force prediction model under the tool flank wear effect in micro-milling nickel-based superalloy. Int J Adv Manuf Technol 91, 3709–3716 (2017). https://doi.org/10.1007/s00170-017-0001-2

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  • DOI: https://doi.org/10.1007/s00170-017-0001-2

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