Identification of Depth -of -Cut Variations and Their Effects on the Process Monitoring for the End Milling Process

In situations where significant cutter deflection is present, a fully-flexible mechanistic end milling force model is proposed to generate simulated force profiles for the DOC variation estimation. The end mill cutter is discretized as a series of elliptical disc elements. Effective cutter geometries, viz., effective helix angle and effective normal rake angle are obtained by investigating the effects of cutter deflection on each disc element. The flexible cutting force is achieved by iteratively solving for chip load that balances the force, cutter deflection and effective cutter geometries. The fully-flexible end milling force model is then applied to the DOC variation detection methodology by constructing force indice databases to relate the force indices to DOC variations. Experimental validation results show that when significant cutter deflection is present in cutting, the fully-flexible end milling force model can significantly improve the accuracy of force prediction in both the magnitude and shape characteristics comparing to other force models; and the DOC variation detection methodology employing the fully-flexible end milling force model can significantly reduce the DOC variation estimation errors comparing to those methodologies employing other force models.

Name thesis:degree_name

Ph.D.

Level thesis:degree_level

Dissertation

Discipline thesis:degree_discipline

Mechanical Engineering

Grantor

University of Illinois at Urbana-Champaign

Year dc:date

2015

Author dc:creator

• Yang, Liuqing

Contributors dc:contributor

• DeVor, Richard E.
• Kapoor, Shiv G.

• Engineering, Industrial

Language dc:language

eng

Identifier

(MiAaPQ)AAI3182429

OAI identifier oai:identifier

oai:www.ideals.illinois.edu:2142/83831