alexa Fourier Analysis of Milling Force for General Helical C
ISSN: 2168-9873

Journal of Applied Mechanical Engineering
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Research Article

Fourier Analysis of Milling Force for General Helical Cutters via Spacetime Convolution, Part 2: Applications for Common Cutters and Model Validation

www.omicsonline.org/applied-mechanical-engineering.phpZheng CM1* and Junz Wang JJ2
1Department of Mechanical and Electrical Engineering, Quanzhou Institute of Information Engineering, Quanzhou 36200, PR China
2Department of Mechanical Engineering, National Cheng Kung University Tainan, 701, Taiwan
*Corresponding Author : Zheng CM
Department of Mechanical and Electrical Engineering
Quanzhou Institute of Information Engineering
Quanzhou 36200, PR China
Tel: 1-86-595-22765
E-mail: [email protected]
Received: December 21, 2015 Accepted: January 21, 2016 Published: January 23, 2016
Citation: Zheng CM, Junz Wang JJ (2016) Fourier Analysis of Milling Force for General Helical Cutters via Space-time Convolution, Part 2: Applications for Common Cutters and Model Validation. J Appl Mech Eng 5:195. doi:10.4172/2168-9873.1000195
Copyright: © 2016 Zheng CM, et al. This is an open-access article distributed under the terms of the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original author and source are credited.
 

Abstract

Part 2 of this study illustrates the applications of the frequency domain force model put forth in Part 1 for three common helical cutters: the square, taper, and ball end mills. The respective geometric and boundary functions required for the evaluation of the force spectra are derived by applying differential geometry to these three types of cutters including cutters of constant helix angle and constant helix lead. By virtue of the explict expression of Fourier coefficients of milling force, the differences between cutting forces generated by two cutters with constant helix angle and constant helix lead can be described quantitatively. In slot (or half slot) milling for the taper end mills with a constant helix angle and constant helix lead, the strategy for selecting axial depths of cut to reduce force pulsation is presented respectively. Also derived are the specific expressions for the average forces of these three helical cutters in common cutting configurations. Moreover, as an inverse application, a linear equation is formulated for the identification of six shearing and ploughing cutting constants from the measured average cutting forces for a general helical cutter. The frequency domain force model and the identification of the cutting constants are finally demonstrated and validated through experiments with all three types of milling cutters.

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