public List <double> ComputeCuttingForces(List <double> toolAngles)
{
CutPropertyCache prop = GetCutProperties();
List <double> results = new List <double>();
double k_z_resolution = Math.Max(0.001, prop.d / 100.0);
double toolradius = prop.tooldiam / 2;
double angleStep = toolAngles[1] - toolAngles[0];
foreach (double angle in toolAngles)
{
double total = 0;
for (double tooth = 0; tooth < prop.teeth; tooth++)
{
double toothStartAngle = angle + 360 * (tooth / prop.teeth);
double toothResult = 0;
for (double z = prop.d; z >= 0; z -= k_z_resolution)
//for (double z = 0; z <= prop.d; z += k_z_resolution)
{
double toothAngle = toothStartAngle + (180 / Math.PI) * (-z) * Math.Tan(prop.helix * (Math.PI / 180)) / toolradius;
toothAngle = wrap(toothAngle, 360);
double engagementAngle = Math.Acos(1.0 - prop.r / toolradius) * (180 / Math.PI);
double engagementStartAngle = 180 - engagementAngle;
double chipThickness = 0;
if (toothAngle > engagementStartAngle && toothAngle < 180)
{
chipThickness = prop.fpt * Math.Sin(toothAngle * (Math.PI / 180));
}
double materialRemoved = chipThickness * k_z_resolution * Math.Sin(angleStep * Math.PI / 180) * toolradius;
toothResult += materialRemoved;
}
total += toothResult;
}
double rpm = 12 * prop.speed / (Math.PI * prop.tooldiam);
double mrr = total * rpm;
double feedfactor = 0.417 * Math.Pow(prop.fpt, -0.197);
double powertool = feedfactor * prop.Kp * prop.wear * mrr;
double powermotor = powertool / prop.E;
double Fc = powertool * 550 / (prop.speed / 60);
results.Add(Fc);
}
return(results);
}
public List <double> ComputeMaterialRemoved(List <double> toolAngles)
{
CutPropertyCache prop = GetCutProperties();
List <double> results = new List <double>();
const double k_z_resolution = 0.001;
double toolradius = prop.tooldiam / 2;
double angleStep = toolAngles[1] - toolAngles[0];
foreach (double angle in toolAngles)
{
double total = 0;
for (double tooth = 0; tooth < prop.teeth; tooth++)
{
double toothStartAngle = angle + 360 * (tooth / prop.teeth);
double toothResult = 0;
for (double z = prop.d; z >= 0; z -= k_z_resolution)
//for (double z = 0; z <= prop.d; z += k_z_resolution)
{
double toothAngle = toothStartAngle + (180 / Math.PI) * (-z) * Math.Tan(prop.helix * (Math.PI / 180)) / toolradius;
toothAngle = wrap(toothAngle, 360);
double engagementAngle = Math.Acos(1.0 - prop.r / toolradius) * (180 / Math.PI);
double engagementStartAngle = 180 - engagementAngle;
double chipThickness = 0;
if (toothAngle > engagementStartAngle && toothAngle < 180)
{
chipThickness = prop.fpt * Math.Sin(toothAngle * (Math.PI / 180));
}
double materialRemoved = chipThickness * k_z_resolution * Math.Sin(angleStep * Math.PI / 180) * toolradius;
toothResult += materialRemoved;
}
total += toothResult;
}
results.Add(total);
}
return(results);
}
public CutPropertyCache GetCutProperties()
{
CutPropertyCache result = new CutPropertyCache();
result.speed = GetPropertyStrict("Cutting Speed");
result.tooldiam = GetPropertyStrict("Tool Diameter");
result.teeth = GetPropertyStrict("Number of Teeth");
result.helix = GetPropertyStrict("Helix Angle");
result.d = GetPropertyStrict("Axial Depth of Cut");
result.r = GetPropertyStrict("Radial Width of Cut");
result.Kp = GetPropertyStrict("Material Power Constant");
result.E = GetPropertyStrict("Power Efficiency");
result.stickout = GetPropertyStrict("Stick out");
result.youngs = GetPropertyStrict("Tool Youngs Modulus");
result.wear = GetPropertyStrict("Tool Wear Factor");
result.fpt = GetPropertyStrict("Feed Per Tooth");
return(result);
}
public double ComputeValue(string name)
{
Dictionary <string, double> results = new Dictionary <string, double>();
CutPropertyCache prop = GetCutProperties();
double rpm = 12 * prop.speed / (Math.PI * prop.tooldiam);
double feedrate = rpm * prop.fpt * prop.teeth;
double mrr = feedrate * prop.d * prop.r;
double feedfactor = 0.417 * Math.Pow(prop.fpt, -0.197);
double powertool = feedfactor * prop.Kp * prop.wear * mrr;
double powermotor = powertool / prop.E;
double Fc = powertool * 550 / (prop.speed / 60);
double Fmax = 1.11 * Fc;
double comparedToSolid = 1.75;
double deflection = (Fc * Math.Pow(prop.stickout, 3)) / (3 * prop.youngs * 145037 * comparedToSolid * Math.Pow(prop.tooldiam, 4) / 64);
double engagementAngle = Math.Acos(1.0 - prop.r / (prop.tooldiam * 0.5)) * (180 / Math.PI);
double chipthicknessAngle = Math.Min(90, engagementAngle);
double chipthickness = prop.fpt * Math.Sin(chipthicknessAngle * Math.PI / 180);
double ultimateTensileStrength = prop.Kp * 292207; // this conversion factor is just a guess based on one datapoint for aluminum
double WoverD = prop.r / prop.tooldiam;
double engagementFactor = lerp(1.0, 1.1, saturate((WoverD - 0.66) / 0.34)); // for aluminum...
Fmax = ultimateTensileStrength * prop.d * prop.fpt * prop.teeth * (engagementAngle / 360) * engagementFactor * prop.wear;
powermotor = Fmax * prop.speed / 33000;
results.Add("Feed Rate", feedrate);
results.Add("RPM", rpm);
results.Add("Material Removal Rate", mrr);
results.Add("Power at Tool 1", powertool);
results.Add("Power at Tool 2", powermotor);
results.Add("Tangential Cutting Force 1", Fc);
results.Add("Tangential Cutting Force 2", Fmax);
results.Add("Deflection of Tool", deflection);
results.Add("Chip Thickness", chipthickness);
return(results[name]);
}