Modelling of cutting force in hard whirling of ball screws based on uncut chip geometry

Hard whirling is a highly efficient and green process for precision ball screw machining. Due to the intermittent cutting characteristics helical motion of tool, forces are periodic time-varying, making it extremely challenging establish an accurate force model. This paper proposes modelling method based on transient geometric uncut chips, subject essential link between chips forces. The time-varying features chip revealed by building 3D digital model chip. An equivalent simulation developed using discrete cross-section chip, effect parameters tool edge investigated. A combination experiment presented identify coefficients, theoretical hard established. results show that cross-sectional area length involved in first increase then decrease, numerical geometry can obtain more combined experimental strategy achieve fast low-cost identification established has good prediction accuracy. study supports investigation mechanism whirling, optimisation improvement machining quality.