Frezeleme İşleminde Kesme Kuvveti Katsayısı Değişiminin İncelenmesi

Öz

Bu çalışma, frezeleme işlemlerinde kesme kuvveti katsayılarının (CFC'ler) değişimini ve bunun kuvvet tahminleri ile kararlılık analizine etkisini incelemektedir. CFC'ler genellikle basitlik adına sabit varsayılmasına rağmen, gerçekte diş başına ilerleme ve kesme hızı gibi parametrelere bağlı olarak değişkenlik göstermektedir. Bu durum, talaşlı imalat dinamiklerinde belirsizliklere yol açmaktadır. Eğik dönüşüm modeli kullanılarak, CFC'ler talaş kalınlığı ve kesme hızı dikkate alınarak ortogonal kesme veritabanından tahmin edilmektedir. Sonuçlar, CFC’lerdeki değişimlerin kesme kuvveti tahminlerini önemli ölçüde etkilediğini ve bu etkinin kararlılık lobu diyagramına (SLD) dayalı kararlılık öngörülerini de etkilediğini göstermektedir. CFC’lerin sabit kabul edilmesi, yanlış kuvvet tahminlerine, hatalı kararlılık limitlerine ve artan titreşim (tırlama) riskiyle sonuçlanabilir. Bu durum, aşırı kesme kuvvetleri, hızlanan takım aşınması, zayıf yüzey kalitesi ve hurdaya ayrılabilecek parçalarla sonuçlanabilir. Bu çalışmada, sabit ve değişken CFC modelleri kullanılarak yapılan kuvvet tahminleri, kesme kuvveti tahminleriyle karşılaştırılmış ve değişken modellere dayalı tahminlerin dinamik frezeleme koşullarında daha isabetli sonuçlar verdiği görülmüştür. Kesme hızı ve diş başına ilerlemenin, teğetsel, radyal ve eksenel kuvvet bileşenlerine etkisi sistematik olarak analiz edilmiştir. Yüksek kesme hızlarının, termal yumuşama etkisi nedeniyle CFC değerlerini azalttığı, buna karşılık artan ilerlemenin talaş yükünü artırarak kuvvet katsayılarını yükselttiği gözlemlenmiştir. CFC değişimlerini dikkate alan bir kararlılık modeli, işlem dinamiklerini daha doğru temsil edebilir. Çalışma, talaşlı imalat simülasyonlarında uyarlanabilir kuvvet ve kararlılık modellerinin önemini vurgulamaktadır. Bu bulgular, süreç parametrelerinin optimizasyonu, kararlı kesme koşullarının seçimi ve endüstriyel uygulamalarda tırlama önleyici stratejilerin geliştirilmesi açısından kritik bilgiler sunmaktadır.

Anahtar Kelimeler

• Kesme kuvveti katsayısı
• kesme kuvveti
• titreşim kararlılığı
• belirsizlik.

Investigation of Cutting Force Coefficient Variation in Milling

Öz

This study investigates the variation of cutting force coefficients (CFCs) in milling operations and their impact on force predictions and stability analysis. While CFCs are often assumed constant for simplicity, they are inherently dependent on feed per tooth and cutting speed, introducing uncertainties in machining dynamics. Using an oblique transformation model, CFCs are predicted from an orthogonal cutting database, considering chip thickness and cutting speed. The results indicate that variations in CFCs significantly influence cutting force estimations, affecting stability predictions based on the stability lobe diagram (SLD). Assuming constant CFCs may lead to inaccurate force predictions, miscalculated stability limits, and increased risk of chatter. This can result in excessive forces, accelerated tool wear, poor surface quality, and potential scrap part. In this study, cutting forces are compared against predictions from both constant and variable CFC models, revealing the improved accuracy of the latter in dynamic milling conditions. The influence of cutting speed and feed per tooth on tangential, radial, and axial force components is systematically analysed. It is observed that higher cutting speeds tend to reduce CFC values due to thermal softening effects, whereas increased feed per tooth generally amplifies force coefficients because of increased chip loads. A stability model incorporating CFC variations may provide a more accurate representation of process dynamics. The study emphasises the necessity of adaptive force and stability models in machining simulations to enhance predictive accuracy. These findings offer critical insights for optimising process parameters, selecting stable cutting conditions, and designing chatter avoidance strategies in industrial applications.

Anahtar Kelimeler

• Cutting force coefficient
• cutting force
• chatter stability
• uncertainty.

Kaynakça

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