Cutting force is a key factor of the cutting plans design, cutting conditions setting, tool wear evaluation and even machined surface topography prediction. However, little research has been conducted on the analysis of cutting force in ultra-precision fly cutting (UPFC). This paper presents a theoretical and experimental study on the cutting force modelling in UPFC of groove. In the present study, an analytic cutting force model has been established to predict the cutting force amplitudes both in the feed direction and thrust direction. Experiments were conducted to verify the simulation results. Theoretical and experimental results show that cutting force in UPFC is figured as a force pulse followed by a series of free vibration signals, cutting parameters such as cutting depth, feed rate seriously affect cutting force amplitude.
Cutting force and its power spectrum analysis was thought to be an effective method monitoring tool wear in many cutting processes and a significant body of research has been conducted on this research area. However, relative little similar research was found in ultra-precision fly cutting. In this paper, a group of experiments were carried out to investigate the cutting forces and its power spectrum characteristics under different tool wear stages. Result reveals that the cutting force increases with the progress of tool wear. The cutting force signals under different tool wear stages were analyzed using power spectrum analysis. The analysis indicates that a characteristic frequency does exist in the power spectrum of the cutting force, whose power spectral density increases with the increasing of tool wear level, this characteristic frequency could be adopted to monitor diamond tool wear in ultra-precision fly cutting.
Conference Committee Involvement (1)
Sixth Asia Pacific Conference on Optics Manufacture (APCOM2019)
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