Modeling and Analysis on Cutting Force in High Speed Milling Aeronautic Aluminum Alloy

Hong Lei Department of Science and Technology, Heilongjiang Institute of Science & Technology, Harbin, China, 150027 lei_h@163.com Wantao He College of Mechanical Engineering, Heilongjiang Institute of Science & Technology, Harbin, China, 150027 hewantao1225@163.com
AbstractIn this paper, a high speed milling test for aeronautic aluminum alloy 2A70 was carried out, and the cutting forces were measured. The least square method was used to make a regression analysis on testing data, and the experiential formulas for high speed milling were established. The influencing laws of cutting parameters on cutting force were educed, which can offer an important reference for optimizing cutting parameters. Keywords- Aeronautic aluminum alloy; high speed milling; cutting force.

Yanyan Guo Center for Engineering Training and Basic Experimentation Heilongjiang Institute of Science & Technology Harbin, China,150027 gyyhist@163.com

II.

EXPERIMENTAL WORK

I.

INTRODUCTION

From 1980s the spindle speed and feed rate of CNC machine tools have improved greatly as a design and manufacturing technology breakthrough of functional components in the spindle and feed rate systems in CNC machine tools. Driven by the modern manufacturing technology, machining technology began to enter a new phase of high speed cutting. At present, the high-speed cutting has been widely used in the mold, aerospace, automotive and other manufacturing areas, and it has produced significant economic benefits and is developing in the other application areas. Milling forces is one of the main factors that affect the workpiece machining accuracy and tool life. It is an important basis in determining the tool - workpiece system deformation, machine chatter, tool wear and failure, tool life and surface integrity. Therefore, it is helpful in analyzing the milling process and solving the metal processing technology problem and it is significant to optimize the cutting parameters by understanding the factors that affect the milling force, establishing a reasonable milling force prediction model to predict the milling force correctly. At present, research on cutting forces is focused on turning process and the ball milling process with usual speed. The research on high-speed milling is rare [1-5]. In this paper, a high speed milling test for aeronautic aluminum alloy 2A70 was carried out, and the cutting forces were measured. The least square method was used to make a regression analysis on testing data, and the experiential formulas for high speed milling were established. The influencing laws of cutting parameters on cutting force were educed, which can offer an important reference for optimizing cutting parameters.
Supported by Scientific Research Fund of Heilongjiang Provincial Education Department (Grant No. 11551431).

A. The experimental principle of cutting force The experimental principle of milling force is shown in Figure 1. A piezo-electric dynamometer was mounted on the worktable of a high-speed five-axis CNC machining center. All the data lines were connected to the computer. In the milling process, the instantaneous cutting forces along x, y, z directions are amplified through a charge amplifier, which in turn is connected to analog to digital converter and the data acquisition hardware/software installed on the computer. The amplified signals from the charge amplifier are fed to data acquisition system where, they are converted to digital output, which subsequently is sent to computer. The cutting tool was mounted on the machine spindle using a tool holding fixture. The three components of cutting forces were measured.

Figure 1. The experimental principle of milling force

B.

Experimental equipments

The milling test were conducted on Mikron HSM(highspeed machining) 600U five-axis CNC machining center in dry condition, which the maximum spindle speed is 42000r/min, the spindle power is 13KW, and the feed rate is 40 m / min. The cutting tool is carbide solid ball-end mill with four teeth. The diameter of the tool is 10mm and its helix angle is =45o. The material of workpiece is aerospace aluminum alloy 2A70.

978-1-4244-9439-2/11/$26.00 2011 IEEE

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TABLE I. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 ap (mm) 3.5 3.83 3.07 4.08 3.13 2.15 2.89 2.57 2.25 1.55 1.79 2.05 1.08 1.27 0.83 1.4 ae (mm) 2 2.5 1.5 3 3 1.5 2.5 2 3 1.5 2.5 2 2 2.5 1.5 3

CUTTING PARAMETERS OF EACH GROUP AND RESULTS OF THE EXPERIMENT n (r/min) 16000 12000 18000 14000 16000 12000 18000 14000 12000 16000 14000 18000 12000 16000 14000 18000 fz (mm) 0.06 0.1 0.08 0.04 0.08 0.04 0.06 0.1 0.06 0.1 0.08 0.04 0.08 0.04 0.06 0.1 Average Cutting forces Fx(N) 44.108 63.716 57.733 36.947 60.173 37.511 57.882 78.195 60.725 25.354 56.168 32.424 16.739 17.296 6.888 37.088 Fy(N) 103.281 122.313 157.272 104.030 157.296 139.141 183.695 150.507 267.821 53.340 138.779 70.006 35.822 25.973 8.220 97.271 Fz(N) 17.328 9.961 14.444 8.068 15.618 17.677 14.010 15.691 9.435 11.242 21.904 20.264 5.775 8.391 2.646 11.231 F(N) 113.6342 138.2730 168.1553 110.6906 169.1353 145.1887 193.1074 170.3321 274.7811 60.1196 151.3084 79.7671 39.9595 32.3134 11.0460 104.7058

The dynamometer is a three component piezo-electric dynamometer (Kistler Corporation, Model9257B). The charge amplifier is a multi-channel charge amplifier(Kistler Corporation, Model 5070A). And industrial personal computer (IPC) is using America National Instruments which model is PXI-1042Q. C. Experimental program In this paper, a series of orthogonal tests during impeller finish machining were designed to solve the experiential formula of the ball-end mill. The cutting part of ball-end mill was mainly the upper half of the ball, therefore, it should be ensured that the upper half of the ball-end mill cutting workpiece in cutting experiments. At the same time, there was only one cutting blade participating in machining at all times. For these situations, experimental machining adopted the horizontal milling, climb-milling, one-way, and the feed direction paralleling to the X-axis direction. Besides, there was no coolant in machining. The experimental milling scheme is shown in Figure 2. By changing the axial depth of cut, radial depth of cut, spindle speed and feed rate per tooth, a series of orthogonal experiments were designed and 16 groups of milling experiments were carried out. According to the measured momentary cutting forces, the average milling forces are calculated on the process of the tool rotates one circle. Cutting parameters of each group and results of the experiment are shown in Table 1.

ae

Y ap

t ( j , , )

fz

Figure 2. Milling scheme

III.

MODELING AND ANALYSIS OF EXPERIENTIAL FORMULA

The data was processed by regression analysis. And the tool experimental formulas in x, y, z directions and the resultant force were obtained respectively.

Fx = 35.1075a p1.0229 ae 0.3850 f z 0.5490 N 0.0494 Fy = 496.1352a p F = 448.1259a p

1.3207

(1) (2)
0.9606

ae

0.5878

fz fz

0.4483

0.2045

Fz = 9.0740 10 a p
1.2388

0.6301

ae

0.1270

fz

0.0598

(3) (4)

ae

0.5440

0.4306

0.1780

From the above formulas, we can see that in the process of the ball-end mill high-speed machining aviation aluminum alloy, the cutting force along y direction influenced the resultant force greatly, while the cutting force along x and z

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direction influenced the resultant force slightly which can be ignored under some certain conditions. From the empirical formula (4) of the resultant force, we can see that in high-speed milling process, the axial depth of cut ap influenced the cutting force greatly(index number:1.2388) which is shown in Figure 3. When the feed per tooth fz = 0.1mm, the spindle speed n = 18000rpm, and the radial depth of cut ae = 2mm, the cutting force increases with the axial depth of cut increasing and the cutting forces rise significantly, and the variety range are high. The influence of the radial depth of cut ae takes the second place (index number:0.5440) which is shown in Figure 4. When the axial depth of cut ap = 1.4mm, the feed per tooth fz = 0.1mm, and the spindle speed n = 18000rpm, the cutting force increases with the radial depth of cut increasing gradually, however, the variety range are gentle. The feed per tooth fz also takes the second place (index number: 0.4306) which is shown in Figure 5. When the axial depth of cut ap = 1.4mm, radial depth of cut ae = 2mm, and the spindle speed n = 18000rpm, the cutting force increases slowly with feed per tooth increasing. The influence of the spindle speed on cutting force is contrary to the above three parameters(index number:-0.1780) which is shown in Figure 6.When the axial depth of cut ap = 1.4mm, the radial depth of cut ae = 2mm, and the feed per tooth fz = 0.1mm, the cutting force reduces with the spindle speed increasing. However, the decline is relatively gentle and its variety range is slightly.
350

150

Cutting Force F(N)

100

50

0.02

0.04 0.06 0.08 Feed per tooth fz(mm)

0.1

0.12

Figure 5. Cutting force changes with the feed per tooth fz

150

Cutting Force F(N)

100

50

1.1

1.2

1.3

1.4 1.5 1.6 Spindle Speed(rpm)

1.7

1.8

1.9 x 10

2
4

300

Figure 6. Cutting force changes with the spindle speed n

250 Cutting Force F(N)

200

IV.

CONCLUSION

150

100

50

0.5

1.5

2 2.5 3 3.5 Axial depth of cut ap(mm)

4.5

Figure 3. Cutting force changes with the axial depth of cut ap

150

In this paper, the cutting forces in high-speed milling aluminum alloy 2A70 process were measured, and the empirical formulas were established through least squares method. It is can be seen from the empirical formulas that in milling 2A70 process, the axial depth of cut influences the cutting force greatly, the radial depth of cut and feed per tooth take the second place, and the cutting force reduces with the increased spindle speed to a lesser extent. According to this, the following conclusions can be obtained that in the actual high-speed milling aluminum alloy 2A70, the finish machining should adopt a higher spindle speed. REFERENCES
[1] Lamikiz A, Lopez de Lacalle L N, Sanchez J A, et al. Cutting force estimation in sculptured surface milling[J]. International Journal of Machine Tools & Manufacture, 2004, 44(14): 1511-1526. Lazoglu I. Sculpture surface machining: a generalized model of ball-end milling force system[J]. International Journal of Machine Tools & Manufacture, 2003, 43(5): 453462. Liu Chao, Ai Xing, Liu Zhanqiang, Wan Yi. Modeling and Analysis on Cutting Force and Surface Roughness in Turning of High Temperature Alloy GIl2132. TOOL ENGINEERING,2009 43(10):19-21. Tang Zhitao, Liu Zhanqiang. Ai Xing Experimentation on the Superficial Residual Stresses Generated by High-speed Milling Aluminum Alloy. CHINA MECHANICAL ENGINEERING, 2008,19(6):699-703.

Cutting Force F(N)

100

50

[2]

[3]
0 0.5 1 1.5 2 2.5 3 3.5 Radial depth of cut ae(mm) 4 4.5 5

Figure 4. Cutting force changes with the radial depth of cut ae

[4]

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[5]

Liu Zhanqiang, Wan Yi, Ai Xing. Study of Cutting Forces in High Speed Milling. CHINA MECHANICAL ENGINEERING, 2003, 14(9) :733-737.

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