A Hybrid Modeling Method for Predicting the Cutting Force in Whirlwind Milling of Lead Screw

Analyzing the cutting force in the process of lead screw whirlwind milling can help us understand the processing quality and processability. Whirlwind milling is a process in which multiple cutting tools are driven by the cutter head to sequentially cut and process the workpiece. The cutting force changes periodically in the process of lead screw whirlwind milling. Analyzing the cutting force of the nth cutting needs to consider the influence of the previous n-1 cutting. This paper employed a hybrid method combining mathematical modeling and finite element analysis to predict the cutting force in lead screw whirlwind milling. Firstly, the tool motion path of lead screw whirlwind milling is analyzed by considering the influence of cutter inclination angle and relative tool-workpiece motion. The relationship between the nth tool path and the (n-1)th tool path is analyzed by considering the feed motion of the tool and the rotation motion of the workpiece. Furtherly, mathematical models of the nth tool path and the (n-1)th tool path are established. Then, based on the established mathematical models, the three-dimensional geometric model of the tool and workpiece is established by three-dimensional software. The establishment of the workpiece geometry model considers the influence of the previous n-1 cutting. The tool geometry model rotates along the (n-1)th cutting path, and the tool intersects the workpiece. Finally, the finite element model of lead screw whirlwind milling is established based on the above three-dimensional geometric model. The periodical cutting force in the lead screw whirlwind milling is obtained by simulating the nth cutting with the finite element model. The relevant lead screw whirlwind milling experiment was carried out to verify the reliability of the model prediction. The appropriate processing parameter range of lead screw whirlwind milling is obtained through the process parameter optimization.