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Modified power prediction model based on infinitesimal cutting force during face milling process

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Abstract

Nowadays soaring energy price, increasing environmental concerns, and stringent legislations make energy saving very emergency and helpful both for enterprises and environment. To deal with these issues, this paper presents a generalized mathematical power prediction model of face milling process used in manufacturing. An attempt was made to develop a relatively precise and direct power consumption model to help researchers make power optimization much easier and more practical than before. First, an infinitesimal cutting force model was proposed based on theoretical and experimental foundations. Secondly, relationship between power consumption and cutting force components was revealed, and power consumption based on infinitesimal cutting forces during metal removal process was developed. Finally, the proposed model was experimentally verified by comparing predicted and measured power consumption. Both average and instantaneous values of power consumption were used to analyze prediction error of the model. This proposed model can be used to evaluate and optimize cutting power consumption once cutting parameters were decided based on minimal energy demand. Results showed that the mean errors of maximum power and mean power were 0.076% and 0.208%, respectively. Otherwise, this proposed model will drive the field of power consumption simulation development.

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Abbreviations

dA:

Cutting area of infinitesimal cutting edge (mm2)

db :

Width of cutting edge element (mm)

d z :

Thickness of infinitesimal cutting edge (mm)

dF c :

Cutting force component normal to the tool rake (N)

dF t :

Cutting force component tangential to the elementary cutting edge (N)

dF n :

Radial cutting force component (N)

F v :

Cutting force component along cutting speed vc (N)

f z :

Feed per tooth of the milling parameters (mm/tooth)

Ktc, Knc, Kcc :

Cutting force coefficients (N/mm2)

Kte, Kne, Kce :

Edge force coefficients (N/mm)

P a-f :

Additional power loss of feed drive system in cutting state (W)

P a-n :

Additional power loss of main drive system in cutting state (W)

P c :

Total cutting power consumption of experiment (W)

P c-idle :

Spindle motor’s power consumption of the auxiliary components in cutting state (W)

P idle :

Spindle motor’s power consumption of the auxiliary components in idling state (W)

P servo :

Feed motion power consumption in cutting state (W)

P spindle :

Total spindle rotational power in cutting state (W)

P remove :

Total power consumption of material removing process (W)

P u :

Unload power of servo motor in feed motion system in stand-by state (W)

r :

The radius of face miller (mm)

t 0 :

Chip thickness (mm)

vc :

Cutting speed (m/min)

vf :

Feeding speed (m/min)

η :

Additional load loss coefficient of spindle system

ϕ(t):

The instantaneous cutting angle (°)

ϕ st :

Cutter entry angle (°)

ϕ ex :

Cutter exit angle (°)

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Authors and Affiliations

  1. School of Mechanical Engineering, Shandong University, Jinan, 250061, China

    Xiaona Luan, Song Zhang & Gang Li

  2. Key Laboratory of High-Efficiency and Clean Mechanical Manufacture (Minisrty of Education), Shandong University, Jinan, 250061, China

    Xiaona Luan, Song Zhang & Gang Li

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  1. Xiaona Luan
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Correspondence to Song Zhang.

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Luan, X., Zhang, S. & Li, G. Modified power prediction model based on infinitesimal cutting force during face milling process. Int. J. of Precis. Eng. and Manuf.-Green Tech. 5, 71–80 (2018). https://doi.org/10.1007/s40684-018-0008-7

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