engleski

A New Method for Tool Engagement Estimation in Machining

Recent developments in the field of tool condition monitoring have evidenced that, even for simple geometries of cut, it is necessary to estimate carefully the uncut chip thickness and the tool engagement for better understanding of the relationship between cutting parameters and cutting forces. In the past, the finite element method was applied to estimate the engagement between the tool and the workpiece. However, the results were not satisfactory, due to the exponential grow of a number of elements. A new approach based on lumped parameters method for tool engagement evaluation is presented. The lumped parameters are organized in a fractal structure in order to limit the number of elements needed for the calculation of the interference between the tool and the workpiece. The new approach is very promising for the simulation of tool engagement and the estimation of cutting forces where the cutting geometry is complex, for example in ball-nose end milling of mould and dies. The main issues of the new approach are presented and some preliminary results of its application for cutting force estimation in milling are illustrated.

Uncut chip thickness estimation; Milling modelling; Milling simulation

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