74
Q. Liu et al.
chip forming data and the drawing of cutting force and temperature when n = 16,000
r/min, f = 400 mm/min, a p = 40 μm. The simulation and experimental parameters
are the data extraction of chip separation, cutting force and temperature of simulation
and experimental cutting Ti6Al4V after the end of the experiment. The results show
that the simulation results of the established tool model are very close to the chip
shape and length values of the experimental results. The results of simulation using
the tool and cutting model attribute parameters are credible [6–12].
6.3.3 Analysis of Cutting Force Comparison
between Simulation and Experiment
10 groups of Single Factors Are Selected for Calculation of Simulation and Experimental Cutting Forces. Finally, the Results Are Compared, as Shown in Table 6.5.
The Error is Calculated as Follows. Equation (6.14)
Error =
x Sim − x Exp
x Exp
× 100%
(6.14)
Figure 6.14 shows the relative error percentage between simulated and experimental cutting forces. Table 6.5 shows that the simulation errors are small except for
the larger errors of the points (test numbers 2, 5 and 6).
In addition, 10 groups of simulation and experimental data can be obtained. Based
on the accurate modeling of milling cutter model, the error of cutting force in three
directions of simulation data and experimental data is less than 15%. It shows that
the consistency of milling cutter model and actual cutter has a direct impact on the
simulation results, and the data is more reliable [12].
6.3.4 Analysis of Cutting Temperature Comparison
between Simulation and Experiment
Figure 6.15 shows the simplified schematic diagram of milling temperature model.
According to the model structure of milling cutter and cutting principle, the milling
cutter can be divided into numerous units along the spiral edge when analyzing the
cutting temperature produced in milling process. The cutting process of each unit can
be simplified as oblique cutting. Figure 6.15a and b show the temperature generated in
the cutting area during milling. Results showed that temperature rise mainly occurred
in three areas during milling, as shown in Fig. 6.15c including cutting area of rake
face where temperature rose resulting from friction behavior between chip and rake
face; cutting area of flank face where temperature increased due to friction between
flank face and the workpiece; and plastic deformation area of the shear surface where
Q. Liu et al.
chip forming data and the drawing of cutting force and temperature when n = 16,000
r/min, f = 400 mm/min, a p = 40 μm. The simulation and experimental parameters
are the data extraction of chip separation, cutting force and temperature of simulation
and experimental cutting Ti6Al4V after the end of the experiment. The results show
that the simulation results of the established tool model are very close to the chip
shape and length values of the experimental results. The results of simulation using
the tool and cutting model attribute parameters are credible [6–12].
6.3.3 Analysis of Cutting Force Comparison
between Simulation and Experiment
10 groups of Single Factors Are Selected for Calculation of Simulation and Experimental Cutting Forces. Finally, the Results Are Compared, as Shown in Table 6.5.
The Error is Calculated as Follows. Equation (6.14)
Error =
x Sim − x Exp
x Exp
× 100%
(6.14)
Figure 6.14 shows the relative error percentage between simulated and experimental cutting forces. Table 6.5 shows that the simulation errors are small except for
the larger errors of the points (test numbers 2, 5 and 6).
In addition, 10 groups of simulation and experimental data can be obtained. Based
on the accurate modeling of milling cutter model, the error of cutting force in three
directions of simulation data and experimental data is less than 15%. It shows that
the consistency of milling cutter model and actual cutter has a direct impact on the
simulation results, and the data is more reliable [12].
6.3.4 Analysis of Cutting Temperature Comparison
between Simulation and Experiment
Figure 6.15 shows the simplified schematic diagram of milling temperature model.
According to the model structure of milling cutter and cutting principle, the milling
cutter can be divided into numerous units along the spiral edge when analyzing the
cutting temperature produced in milling process. The cutting process of each unit can
be simplified as oblique cutting. Figure 6.15a and b show the temperature generated in
the cutting area during milling. Results showed that temperature rise mainly occurred
in three areas during milling, as shown in Fig. 6.15c including cutting area of rake
face where temperature rose resulting from friction behavior between chip and rake
face; cutting area of flank face where temperature increased due to friction between
flank face and the workpiece; and plastic deformation area of the shear surface where