Abstract
Determination of cutting forces is the main requirement for understanding the machining process and optimising its parameters for achieving higher productivity and surface finish. This paper presents an exploratory study and the development of a model to estimate cutting forces for a 3-axis CNC milling process using a voxel-based CAD model. The developed algorithm takes the NC code, workpiece/tool material properties, and the tool geometry data as inputs. The cutting tool engagement with the workpiece is computed using a discretized (voxelized) model. The calculated voxel engagement was finally used to calculate the cutting forces using the analytical method. The algorithm was implemented and tested for various case studies and the in-house experimental data for different types of end mill tools. Finally, the effect of variation in the size of the voxel and the number of flutes was studied. The model showed a good correlation and was found to be accurate (~80%) and robust.
Original language | English |
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Pages (from-to) | 665-676 |
Number of pages | 12 |
Journal | Advances in Materials and Processing Technologies |
Volume | 9 |
Issue number | 2 |
Early online date | 3 Jul 2022 |
DOIs | |
Publication status | Published - 31 Dec 2023 |
Keywords
- 3-axis CNC machining
- force prediction
- Process modelling
- Voxelization
ASJC Scopus subject areas
- General Materials Science
- Mechanics of Materials
- Industrial and Manufacturing Engineering