Force predictive model for five-axis ball end milling of sculptured surface

2018 ◽  
Vol 98 (5-8) ◽  
pp. 1367-1377 ◽  
Author(s):  
Z. C. Wei ◽  
M. L. Guo ◽  
M. J. Wang ◽  
S. Q. Li ◽  
S. X. Liu
Keyword(s):  
Predictive Model ◽  
End Milling ◽  
Sculptured Surface ◽  
Ball End Milling ◽  
Five Axis

Tool Orientation Planning in Milling With Process Dynamic Constraints: A Minimax Optimization Approach

2018 ◽  
Vol 140 (11) ◽  
Author(s):  
Tao Huang ◽  
Xiao-Ming Zhang ◽  
Jürgen Leopold ◽  
Han Ding
Keyword(s):  
Tool Path ◽  
End Milling ◽  
Tool Path Generation ◽  
Optimization Approach ◽  
Path Generation ◽  
Tool Orientation ◽  
Minimax Optimization ◽  
Ball End Milling ◽  
Dynamic Constraints ◽  
Five Axis

In five-axis milling process, the tool path generated by a commercial software seldom takes the dynamics of the machining process into account. The neglect of process dynamics may lead to milling chatter, which causes overcut, quick tool wear, etc., and thus damages workpiece surface and shortens tool life. This motivates us to consider dynamic constraints in the tool path generation. Tool orientation variations in five-axis ball-end milling influence chatter stability and surface location error (SLE) due to the varying tool-workpiece immersion area and cutting force, which inversely provides us a feasible and flexible way to suppress chatter and SLE. However, tool orientations adjustment for suppression of chatter and SLE may cause drastic changes of the tool orientations and affects surface quality. The challenge is to strike a balance between the smooth tool orientations and suppression of chatter and SLE. To overcome the challenge, this paper presents a minimax optimization approach for planning tool orientations. The optimization objective is to obtain smooth tool orientations, by minimizing the maximum variation of the rotational angles between adjacent cutter locations, with constraints of chatter-free and SLE threshold. A dedicated designed ball-end milling experiment is conducted to validate the proposed approach. The work provides new insight into the tool path generation for ball-end milling of sculpture surface; also it would be helpful to decision-making for process parameters optimization in practical complex parts milling operations at shop floor.

Surface Topography and Roughness Simulations for 5-Axis Ball-End Milling

2009 ◽  
Vol 69-70 ◽  
pp. 471-475 ◽  
Author(s):  
Shi Guo Han ◽  
Jun Zhao ◽  
Xiao Feng Zhang
Keyword(s):  
Surface Topography ◽  
Surface Quality ◽  
High Speed ◽  
End Milling ◽  
Analytical Form ◽  
Influential Factors ◽  
Sculptured Surfaces ◽  
Machined Surface ◽  
Ball End Milling ◽  
Five Axis

In five-axis high speed milling of freeform surface with ball-end cutters, unwanted machining results are usually introduced by some error effects. Hence precise modeling and simulation of milled sculptured surfaces topography and roughness is the key to obtain optimal process parameters, satisfactory surface quality and high machining efficiency. In this paper, a predictive model for sculptured surface topography and roughness of ball-end milling is developed. Firstly, a mathematical model including both the relative motion of the cutter-workpiece couple and some influential factors on machined surface quality such as the tool runout, tool deflection and tool wear is proposed, and subsequently the analytical form of the tool swept envelope is derived by means of homogeneous coordinate transformation. Then the minimal z-values of the corresponding points lied in discrete cutting edges model and Z-map workpiece model are used to update the workpiece surface topography and to calculate 3D surface roughness. Finally, the simulation algorithm is realized with Matlab software. A series of machining tests on 3Cr2MoNi steel are conducted to validate the model, and the machined surface topography is found in good accordance with the simulation result.

Curve-Curve Contact in 5-Axis NC Machining of Sculptured Surfaces Using Flat-End Cutter

2008 ◽  
Author(s):  
Hu Ran Liu
Keyword(s):  
Differential Geometry ◽  
End Milling ◽  
Curved Surface ◽  
Sculptured Surface ◽  
Sculptured Surfaces ◽  
End Mill ◽  
Ball End Mill ◽  
Ball End Milling ◽  
Swept Surface ◽  
Complicated Surface

The concept of “contact” in differential geometry is creatively applied into the machining of the sculptured surface; the contact principle of the machining of complicated surfaces is presented. The circumference circle of the cylindrical cutter instead of ball-end milling cutter is used to sweep the curved surface. This is the highly effective method. In this paper an innovative theory for machining complicated surface is presented. By using a flat-end mill instead of ball-end mill, and by adjusting the axis of cutter relative to the surface, the two surfaces, the swept surface and the required surface, have the same curvatures, up to as high as 3rd order. It shows how aspects of 5-axos machining can be achieved through 3-axis methods. This is useful as not all shops can afford 5-axis machining.

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