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An instantaneous cutting force model for disc mill cutter based on the machining blisk-tunnel of aero-engine

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Abstract

This paper presents an instantaneous cutting force prediction model for a disc mill cutter with indexable inserts. Cutting characteristics, including the normal friction angles, normal shear angles, and shear stress, are decisive factors in determining the instantaneous cutting force coefficients. The cutting characteristics can be determined by several specialized milling experiments, instead of the numerous orthogonal turning experiments that are traditionally used. In this study, the normal friction angles, normal shear angles, and shear stress are determined by a coordinate transformation of the cutting forces and the geometrical parameters of oblique cutting. Then, experiments were used to verify the cutting forces model. The results clearly indicate that shear stress can be described by a constant, nevertheless distributive law of normal shear angle and friction angle fit exponential functions of instantaneous uncut chip thickness. In conclusion, the presented model was found to successfully and accurately forecast the cutting forces of the disc mill cutter with indexable inserts under various machining conditions.

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Funding

This paper was supported by the National Science and Technology Major Project of China (grant no. 2013ZX04001-081).

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Authors and Affiliations

  1. The Key Laboratory of Contemporary Design and Integrated Manufacturing Technology, Ministry of Education, Northwestern Polytechnical University, Xi’an, 710072, China

    Nan Zhang, Yaoyao Shi, Cheng Yang, Zhen Chen, Chao Kang & Jie Luo

  2. School of Mechanical Engineering, Inner Mongolia University of Technology, Hohhot, 010051, China

    Nan Zhang

Authors
  1. Nan Zhang
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  2. Yaoyao Shi
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  3. Cheng Yang
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  4. Zhen Chen
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  5. Chao Kang
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  6. Jie Luo
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Correspondence to Yaoyao Shi.

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Zhang, N., Shi, Y., Yang, C. et al. An instantaneous cutting force model for disc mill cutter based on the machining blisk-tunnel of aero-engine. Int J Adv Manuf Technol 99, 233–246 (2018). https://doi.org/10.1007/s00170-018-2434-7

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  • DOI: https://doi.org/10.1007/s00170-018-2434-7

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