Modeling And Analysis Of Cutting Forces In Orthogonal Turn-milling Of Shaft Parts

Turn-milling can be an important process to manufacture aircraft parts in one machinetool,solving the problem of digital manufacturing shaft parts.Turn-milling is a high-precisionprocess,costing less time.Orthogonal turn-milling completes the process of the shaft partsthrough the movement combined the rotary motion of the workpiece and the rotary motionof the mill cutter,with the advantage of multi-process machining in the one clamping.In orderto optimize the orthogonal turn-milling process parameters and improve the efficiency,cutting forces of orthogonal turn-milling need to be studied.In this paper,the cutting forcesare researched in regard to orthogonal turn-milling shaft parts.The details are as follows.Firstly,analyze the procedure and kinematics of orthogonal turn-milling.Secondly,theundeformed chip’s geometric is modeling,including the chips generated respectively bycircumference edges and bottom edges.Calculation models are derived about circumferenceedges and bottom edges of infinitesimal chip thickness,micro-element cutting depth andmicro-element lead angles. Thirdly,cutting forces of orthogonal turn-milling are studiedbased on the analysis of micro chips’ geometry.Discrete circumference edges intoinfinitesimal Along the cutter’s axis,and infinitesimal cutting forces of circumferential edgesare calculating.With a step function to judge the limits of integration to get instantaneouscutting forces of circumference edges,cutting forces of circumference edges are calculatedand modeled.On the basis of this model,analyze cutting forces of bottom edges.Alongcutter’s radial dsicrete bottom edges into micro-elements,and cutting forces of bottom edgesare calculated and modelled.also investigate the influence of the cutter’s run-out onforces.Finally,design experiments verify the theoretical models.based on the verifiedmodels,the impact on cutting forces is analyzed of the variable cutting depth and eccentricitywhich is between the cutter and workpiece.The study provides a theoretical basis about cutting forces to optimize the processingparameters,and models to prodict cutting forces in orthogonal turn-milling of shaft parts.