Cutting force modeling and optimization in three-dimensional plane surface machining

The prediction and optimization of cutting forces in the finish machining of 3D plane surface using ball-end milling are presented in this thesis. The cutting force model is developed based on the mechanistic modeling approach. The objective is to accurately model the cutting forces for non-horizontal and cross-feed cutter movements in 3D finishing ball-end milling. Main features of the model include: (1) a robust cut geometry identification method to establish the complicated engaged area on the cutter; (2) a generalized algorithm to determine the undeformed chip thickness for each engaged cutting edge element; and (3) a comprehensive empirical chip-force relationship to characterize non-horizontal cutting mechanics. Experimental results have shown that the present model gives excellent predictions of cutting forces in 3D ball-end milling.;Optimization of the cutting forces is used to determine both the tool path and the maximum feedrate in 3D plane surface finish machining. An integrated process planning method based on cutting force optimization for the concurrent optimization of tool path and feedrate for the finish machining of 3D plane surfaces using ball-end milling is presented. This method is based on the evaluation of machining errors caused by cutting forces and cutting system deflections. Optimum tool path and feedrate are established when the machining process is carried out at the highest possible efficiency and the resulting machining errors are maintained within the specified tolerance limits. The integrated optimization method determines the optimum cutter feed direction that corresponds to the optimum tool path and feedrate. Simulation results have indicated that the optimum cutter feed direction is often not unique but falls within an optimum range in 3D plane surface finishing machining.