Indirect approach for predicting cutting force coefficients and power consumption in milling process

doi:10.1007/s40436-021-00370-1

Advances in Manufacturing ›› 2022, Vol. 10 ›› Issue (1): 101-113.doi: 10.1007/s40436-021-00370-1

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Indirect approach for predicting cutting force coefficients and power consumption in milling process

Kai-Ning Shi^1,2, Ning Liu³, Cong-Le Liu^1,2, Jun-Xue Ren^1,2, Shan-Shan Yang³, Wei Chit Tan³

1 Key Laboratory of High Performance Manufacturing for Aero Engine, Department of Mechanical Engineering, Ministry of Industry and Information Technology, Northwestern Polytechnical University, Xi'an, 710072, People's Republic of China;
2 Engineering Research Centre of Advanced Manufacturing Technology for Aero Engine, Department of Mechanical Engineering, Ministry of Education, Northwestern Polytechnical University, Xi'an, 710072, People's Republic of China;
3 Virtual Manufacturing Group, Smart Manufacturing Division, Advanced Remanufacturing and Technology Centre, 3 Cleantech Loop, #01-01, CleanTech Two, Singapore, 637143, Singapore

Received:2021-03-09 Revised:2021-04-24 Online:2022-03-25 Published:2022-02-23
Contact: Ning Liu E-mail:Liu_Ning@artc.a-star.edu.sg
Supported by:
The authors would like to acknowledge the financial support provided by the National Natural Science Foundation of China (Grant Nos. 51905442, 51775444), the Fundamental Research Funds for the Central Universities (Grant No. 31020190502006), and the National Science and Technology Major Project (Grant No. J2019-VII-0001-0141).

Abstract

Abstract: Accurate energy consumption modeling is an essential prerequisite for sustainable manufacturing. Recently, cutting-power-based models have garnered significant attention, as they can provide more comprehensive information regarding the machining energy consumption pattern. However, their implementation is challenging because new cutting force coefficients are typically required to address new workpiece materials. Traditionally, cutting force coefficients are calculated at a high operation cost as a dynamometer must be used. Hence, a novel indirect approach for estimating the cutting force coefficients of a new tool-workpiece pair is proposed herein. The key idea is to convert the cutting force coefficient calculation problem into an optimization problem, whose solution can be effectively obtained using the proposed simulated annealing algorithm. Subsequently, the cutting force coefficients for a new tool-workpiece pair can be estimated from a pre-calibrated energy consumption model. Machining experiments performed using different machine tools clearly demonstrate the effectiveness of the developed approach. Comparative studies with measured cutting force coefficients reveal the decent accuracy of the approach in terms of both energy consumption prediction and instantaneous cutting force prediction. The proposed approach can provide an accurate and reliable estimation of cutting force coefficients for new workpiece materials while avoiding operational or economic problems encountered in traditional force monitoring methods involving dynamometers. Therefore, this study may significantly advance the development of sustainable manufacturing.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-021-00370-1

Key words: Sustainable manufacturing, Cutting force coefficients, Energy consumption, Machining process, Simulated annealing

Kai-Ning Shi, Ning Liu, Cong-Le Liu, Jun-Xue Ren, Shan-Shan Yang, Wei Chit Tan. Indirect approach for predicting cutting force coefficients and power consumption in milling process[J]. Advances in Manufacturing, 2022, 10(1): 101-113.

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Indirect approach for predicting cutting force coefficients and power consumption in milling process

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